Harley Davidson 2005 touring models. Service repair manual — page 59

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click (latch), press on one side of the connector until that

latch engages, then press on the opposite side to

engage the other latch.

NOTES

●

Deutsch connectors are colored coded for location pur-

poses. Those connectors associated with left side

accessories, such as the front and rear left turn signals,

Figure 8-22. Deutsch Connector Pick Tool

are gray. All other connectors, including those associ-

(Part No. HD-41475-100)

ated with right side accessories, are black.

●

If it should become necessary to replace a plug or

Gently depress terminal latches inside pin housing and

receptacle, please note that the 8-place and 12-place

back out pins through holes in wire seal.

gray and black connectors are not interchangeable.

NOTE

Since location of the alignment tabs differ between the

black and gray connectors, plugs or receptacles must be

If new terminals must be installed, see CRIMPING

replaced by those of the same color. If replacing both the

INSTRUCTIONS on this page.

socket and pin halves, then the black may be substituted

for the gray, and vice versa. The socket and pin halves of

Fit wire seal into back of pin housing. Grasp crimped pin

approximately 1 inch (25.4 mm) behind the contact bar-

all other connectors are interchangeable, that is, the

black may be mated with the gray, since the alignment

rel. Gently push pins through holes in wire seal into their

respective numbered locations. Feed pin into chamber

tabs are absent and the orientation of the external latch

is the same.

until it “clicks” in place. Verify that pin will not back out of

chamber; a slight tug on the wire will confirm that it is

Fit the attachment clip to the pin housing, if removed.

properly locked in place.

Place large end of slot on attachment clip over T-stud on

Insert tapered end of secondary locking wedge into pin

frame. Push assembly forward to engage small end of

housing and press down until it snaps in place. The

slot.

wedge fits in the center groove within the pin housing

and holds the terminal latches tightly closed.

NOTE

CRIMPING INSTRUCTIONS

While rectangular wedges do not require a special orienta-

tion, the conical secondary locking wedge of the 3-place con-

nector must be installed with the arrow pointing toward the

Use the Deutsch Terminal Crimp Tool (HD-39965) to install

external latch. See Figure 8-20.

standard size terminals with crimp tails, as described under

Standard Terminals below. To install the mini-Deutsch termi-

NOTE

nals with crimp tails, see Mini Terminals, which follows. To

If the secondary locking wedge does not slide into the

install those terminals without crimp tails, both standard and

installed position easily, verify that all terminals are fully

mini-Deutsch, use the Deutsch Solid Barrel Contact Crimp

installed in the pin housing. The lock indicates when termi-

Tool (HD-42879) as described under Solid Barrel Contacts.

nals are not properly installed by not entering its fully

installed position.

NOTE

A Deutsch Connector Service Kit (HD-41475) contains a

selection of wire seals, internal seals, seal plugs, secondary

ASSEMBLING/INSTALLING

locking wedges, attachment clips and socket/pin terminals.

Also included is a compartmented storage box, carrying case

and pick tool (HD-41475-100) used for the removal of all

1. Insert socket housing into pin housing until it snaps in

types of locking wedges.

place. Two-, three-, four- and six-place Deutsch connec-

tors have one external latch on the socket half of the

connector. To fit the halves of the connector together, the

latch on the socket side must be aligned with the latch

Standard Terminals

cover on the pin side.

For those connectors with two external latches (8-place

1. Obtain the DEUTSCH TERMINAL CRIMP TOOL (HD-

and 12-place), a different system is used to prevent

39965).

improper assembly. Align the tabs on the socket housing

2. Squeeze the handles to cycle the crimp tool to the fully

with the grooves on the pin housing. Push the connector

open position. See Figure 8-23.

halves together until the latches “click.” If latches do not

8-16

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f1516x8x

Gauge

Nest of

Wire

Crimp Tool

Front

16-18

Middle

Locking

Bar

1. Insert contact through hole of locking bar

2. Insert stripped lead until it contacts

so that barrel rests on nest of crimp tool.

locking bar.

3. Close and squeeze crimp tool.

4. Raise locking bar and remove contact.

Insulation crimp

Core crimp

5. Inspect quality of core and insulation crimps.

f1558x8x

Figure 8-23. Deutsch Crimping Procedure

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8-17

HOME

Raise the locking bar by pushing up on bottom flange.

Solid Barrel Contacts

With the crimp tails facing upward, insert contact

(socket/pin) through hole of locking bar, so that the

For Size 20, 16 and 12 Contacts

rounded side of the contact barrel rests on the nest (con-

Wire Range 26-12 AWG

cave split level area) of the crimp tool. Use the middle

hole in the locking bar for 16-18 gauge wire, the front

Obtain the DEUTSCH SOLID BARREL CONTACT

hole for 20 gauge wire.

CRIMP TOOL (HD-42879).

Release locking bar to lock position of contact. If the

Squeeze the handles to cycle the crimp tool to the fully

crimp tails are slightly out of vertical alignment, the crimp

open position.

tool automatically rotates the contact so that the tails

face straight upward. When correctly positioned, the

Remove locking pin from selector knob. See Figure 8-

locking bar fits snugly in the space between the contact

24.

band and the core crimp tails.

Raise selector knob and rotate until selected wire size

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

stamped on wheel is aligned with “SEL. NO.” arrow. See

Insert wires between crimp tails until ends make contact

upper frame of Figure 8-25.

with locking bar. Verify that wire is positioned so that

Loosen knurled locknut and turn adjusting screw clock-

short pair of crimp tails squeeze bare wire strands, while

wise (in) until it stops.

long pair folds over insulation material.

Squeeze handle of crimp tool until tightly closed. Tool

Turn tool over and drop contact into indentor cover hole

automatically opens when the crimping sequence is

with the wire end out.

complete. Raise up locking bar and remove contact.

Turn adjusting screw counterclockwise (out) until contact

Inspect the quality of the core and insulation crimps. Dis-

is flush with bottom of depression in indentor cover.

tortion should be minimal.

Tighten knurled locknut.

Slowly squeeze handles of crimp tool until contact is

centered between indentor points. See middle frame of

Figure 8-25.

Mini Terminals

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

Obtain the PACKARD TERMINAL CRIMP TOOL (HD-

10.

Insert bare wire strands into contact barrel. See lower

38125-7).

frame of Figure 8-25.

Strip wire lead removing 5/32 inch (4.0 mm) of insula-

tion.

11.

Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is

Compress handles until ratchet automatically opens.

complete.

NOTE

12.

Remove crimped contact from indentor.

Always perform core crimp before insulation crimp.

13.

Inspect the quality of the crimp. Verify that all wire

Position the core crimp on nest E of the crimping tool. Be

strands are in crimp barrel.

sure the core crimp tails are facing the forming jaws.

Gently apply pressure to handles of tool until crimpers

just secure the core crimp tails.

Insert stripped wire between crimp tails. Verify that wire

Adjusting

is positioned so that short pair of crimp tails squeeze

Locking

Screw

bare wire strands, while long pair is positioned over the

Pin

insulation material.

Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is

complete.

Position the insulation crimp on nest C of the crimping

tool. Be sure the insulation crimp tails are facing the

forming jaws.

Selector

Squeeze handle of crimp tool until tightly closed. Tool

Locknut

Knob

f1535x8x

automatically opens when the crimping sequence is

complete.

Figure 8-24. Deutsch Solid Barrel Contact Crimp Tool

10.

Inspect the quality of the core and insulation crimps. Dis-

(Part No. HD-42879)

tortion should be minimal.

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NOTE

Rotate selector knob to align wire size on wheel

with arrow stamped in tool.

Tool must be readjusted when changing contact size/type.

14. Install pin to lock position of selector knob.

Selector

Knob

f1534x8x

Turn adjusting screw as described in text. When

contact is flush with bottom of depression in

indentor cover, squeeze handles to center contact

between indentor points.

Indentor

Cover

Contact

Indentor

Points

f1532x8x

Insert bare wire strands into contact barrel.

Squeeze handle of crimp tool until tightly closed.

f1533x8x

Figure 8-25. Deutsch Solid Barrel Contact

Crimping Procedure

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1-PLACE CABLE CONNECTOR

General

Use the following instructions to service the voltage regulator

cable connector.

Removal

1. Depress external latch and separate pin and socket

halves of connector.

7786

2. Pull rear wire seal from back of housing and slide down

voltage regulator cable to move out of the way.

3. Obtain terminal pick tool (Deutsch® 114008) like that

shown in A of Figure 8-26.

CAUTION

Rough handling or careless storage can result in tool

damage. Exercise care to avoid cracking or breaking the

thin plastic construction.

Install terminal pick tool onto voltage regulator cable so

that the tapered end is in the wire end of the housing.

See B of Figure 8-26.

7787

Push tool into wire end of housing until it bottoms. Gen-

tly tug on housing to pull from terminal. See C of Figure

8-26.

Remove tool from voltage regulator cable.

Installation

Insert terminal into wire end of housing until it “clicks” in

place. Verify that terminal will not back out of housing. A

slight tug on the voltage regulator cable will confirm that

it is properly locked in place.

Fit rear wire seal into back of housing.

Mate pin and socket halves of connector.

7788

Figure 8-26. Remove Socket/Pin Housing

8-20

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AMP MULTILOCK ELECTRICAL CONNECTORS

8.3

is engaged but then inadvertently released. Repeat the

REMOVING SOCKET/PIN

step without releasing the tang.

TERMINALS

NOTE

1. Remove connector from the retaining device, either

An Electrical Terminal Crimp Tool (Part No. HD-41609) is

attachment or rosebud clip.

used to install Amp Multilock pin and socket terminals on

wires. If new terminals must be installed, see CRIMPING

2. Depress the button on the socket terminal side of the

INSTRUCTIONS in this section.

connector

(plug) and pull apart the pin and socket

halves. See Figure 8-27.

3. Bend back the latch slightly and free one side of second-

INSTALLING SOCKET/PIN

ary lock, then repeat the step to release the other side.

Rotate the secondary lock outward on hinge to access

TERMINALS

terminals in chambers of connector housing.

4. Looking in the terminal side of the connector (opposite

NOTE

the secondary lock), take note of the cavity next to each

For wire location purposes, numbers are stamped into the

terminal.

secondary locks of both the socket and pin housings. See

5. See Figure 8-28. With the flat edge against the terminal,

Figure 8-30.

insert the pick (Snap-On TT600-3) into the cavity until it

stops. Pivot the end of the pick away from the terminal

From the secondary lock side of the connector, insert the

and gently tug on wire to pull terminal from chamber. Do

terminal into its respective numbered chamber until it

not tug on the wire until the tang is released or the termi-

snaps in place. For proper fit, the slot in the terminal

nal will be difficult to remove. A “click” is heard if the tang

must face the tang in the chamber.

Secondary Lock

NOTE

Open

For exploded views of 3-place

and

6-place Amp Multilock

connectors, see Figure 8-31.

Pin Terminal

Button

Secondary Lock

Latch

Open

Latch

Pin Housing

Socket Housing

Socket Terminal

Latch

Secondary Lock

f1292x2x

Open

Figure 8-27. 10-Place Amp Multilock Connector (Exploded View)

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HOME

Secondary Lock

Open

f1289x2x

Socket Terminal

Socket Housing

Pick Tool

Pin Terminal

Secondary Lock

Open

Pick Tool

Pin Housing

1. Open Secondary Lock.

2. Insert Pick into Cavity on Mating End of Connector.

3. Pivot End of Pick to Release Tang.

4. Gently Tug on Wire to Remove Terminal from Housing.

Figure 8-28. Release Tang and Back Out Terminals

NOTE

The tang in the chamber engages the slot to lock the terminal

Pin Housing

Tang

Button

in position. On the pin side of the connector, tangs are posi-

tioned at the bottom of each chamber, 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

chamber, so the socket terminal slot (on the same side as the

crimp tails) must face upward. Up and down can be deter-

mined by the position of the release button (used to separate

the pin and socket halves), the button always being the top of

the connector. See Figure 8-29.

2. Gently tug on wire end to verify that the terminal is

Tang

Socket Housing

f1428x8x

locked in place and will not back out of chamber.

Figure 8-29. Tang Location (Cross Sectional View)

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f1287x2x

Secondary Locks Open

- AMP

3-Place Connector

6-Place Connector

10-Place Connector

Figure 8-30. Numbers Stamped on Secondary Locks for Wire Color Locations (Socket Housings Shown)

f1291x2x

3-Place Connector

6-Place Connector

Socket Side

Socket Terminal

Secondary Lock (Open)

Latch

Socket Housing

Button

Pin Side

Pin housing

Latch

Secondary Lock (Open)

Pin Terminal

f1288x2x

Figure 8-31. 3-Place and 6-Place Amp Multilock Connectors

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Locking Bar

f1286x2x

Insulation

Core

Groove

Crimp Tail

Insulation

Crimp Tail

Core

Locking Bar

Crimp Tail

Groove

Tang Slot

PIN TERMINAL

Tang Slot

SOCKET TERMINAL

f1290a2x

Locking

Bar

1. Raise locking bar and seat contact on nest

2. Insert stripped lead until it contacts

of crimp tool. Release locking bar.

locking bar.

Gauge

Nest of

Wire

Crimp Tool

Front

Middle

Rear

3. Close and squeeze crimp tool.

4. Raise locking bar and remove contact.

Figure 8-32. Amp Multilock Crimping Procedure

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Rotate the hinged secondary lock inward until tabs fully

CRIMPING INSTRUCTIONS

engage latches on both sides of connector.

Insert the socket housing (plug) into the pin housing

Squeeze the handles to cycle the crimp tool (Part No.

(receptacle) until it snaps in place.

HD-41609) to the fully open position.

Install connector on retaining device, either attachment

Raise locking bar by pushing up on bottom flange. With

or rosebud clip.

the crimp tails facing upward, insert contact (socket/pin)

through locking bar, so that the closed side of the con-

tact rests on the nest (concave split level area) of the

crimp tool). Use the front nest for 20 gauge wire, the

middle for 16 gauge and the rear for 18 gauge. See Fig-

ure 8-32.

Release locking bar to lock position of contact. When

correctly positioned, the locking bar fits snugly in the

space at the front of the core crimp tails.

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

Insert wires between crimp tails until ends make contact

with locking bar. Verify that wire is positioned so that

short pair of crimp tails squeeze bare wire strands, while

long pair folds over insulation material.

Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is

complete. Raise up locking bar and remove contact.

Inspect the quality of the core and insulation crimps. Dis-

tortion should be minimal.

2005 Touring: Wiring

8-25

HOME

PACKARD ELECTRICAL CONNECTORS

8.4

150 METRI-PACK SERIES

General

2-Place

Use these instructions to service the following connectors:

● MAP Sensor [80B]

● Ignition Coil [83B/130B]

IAT Sensor Connector [89B]

● IAC Actuator [87B]

● TP Sensor [88B]

● ET Sensor [90B]

2-Place

● IAT Sensor [89B]

Disassembly

Remove the connector from the retaining device, if

ET Sensor Connector [90B]

present.

Bend back the external latch(es) slightly and separate

the pin and socket halves of the connector.

To free a pull-to-seat terminal from the connector hous-

ing, first look into the mating end of the connector to find

3-Place

the locking tang. See A in Figure 8-34. The tangs are

always positioned in the middle of the chamber and are

on the same side as the external latch. On those con-

nectors with locking ears, the tang is on the side oppo-

site the ear. See Figure 8-35.

TP Sensor Connector [88B]

At a slight angle, gently insert the point of a one inch

safety pin down the middle of the chamber about 1/8

inch (3.2 mm), and pivot the end of the pin toward the

terminal body. When a click is heard, remove the pin and

repeat the procedure. See B in Figure 8-34. The click is

the sound of the tang returning to the locked position as

4-Place

it slips from the point of the pin. Pick at the tang in this

manner until the clicking stops and the pin seems to

slide in at a slightly greater depth than it had previously.

This is an indication that the tang has been depressed.

NOTE

IAC Connector [87B]

On those terminals that have been extracted on a previous

occasion, no clicking sound may be heard when the pin is

pivoted to depress the tang, but proceed as if the clicking is

Figure 8-33. Packard External Latch Type Connectors

audible and then push on the wire end of the lead to check if

(Socket Sides)

the terminal is free.

NOTE

Remove the pin and push on the wire end of the lead to

When picking multiple terminals, the end of the pin may

extract the terminal from the mating end of the connec-

become malleable. For best results, continue the procedure

tor. See C in Figure 8-34. If necessary, pull back the con-

with a new safety pin.

duit and remove the wire seal at the back of the

connector to introduce some slack in the wires.

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f1360x8x

Locate tang on latch side of chamber.

Push on wire end of lead to remove terminal.

Pivot end of pin to depress tang.

Raise tang and re-install terminal.

Figure 8-34. Depress Tang and Extract Terminal From Mating End of Connector

6. If necessary, crimp new terminals on wires. See Crimp-

2. Gently pull on the lead at the wire end of the connector

ing Instructions at the end of this section.

to draw the terminal back into the chamber. A click is

heard when the terminal is properly seated.

3. Push on the lead to verify that the terminal is locked in

Assembly

place.

NOTE

4. Push the pin and socket halves of the connector

For wire location purposes, alpha characters are stamped

together until the latches “click.”

into the socket housings.

1. Using a thin flat blade, like that on an X-Acto knife, care-

fully bend the tang outward away from the terminal body.

280 METRI-PACK SERIES

See D in Figure 8-34.

General

Use these instructions to service the following:

● Front/Rear Fuel Injectors [84B/85B]

● System Fuse Block [64B]

Fuel Injectors

Disassembly

1. Depress the wireform and use a rocking motion to

detach the electrical connector.

Figure 8-35. Packard Pull-to-Seat Terminal Connector

With Locking Ear

2. Pry rubber seal from wire end of connector and move

seal down wires toward conduit.

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8-27

HOME

f2012x9x

A. Insert safety pin at wire end of

C. Raise tang with blade of X-Acto

connector to depress tang.

knife.

B. Push on wire end of lead to

D. Pull on wire end of lead to draw

remove terminal.

terminal back into chamber.

Figure 8-36. Extract/Install Socket Terminal at Mating End of Connector

Hold the connector so that the wireform is facing down,

Gently pull on the lead at the wire end of the connector

and looking into the wire end of the connector, insert the

to draw the terminal back into the chamber. Be sure that

point of a safety pin between the top of the terminal and

the tang faces opposite the wireform as it enters the

the inside chamber wall.

chamber. A “click” is heard when the terminal is properly

Push safety pin completely into chamber while watching

seated. See D in Figure 8-36.

terminal on mating end of connector. When terminal is

Push on lead to verify that terminal is locked in place.

observed moving forward slightly, then tang is

depressed. See A in Figure 8-36. Remove safety pin.

Fit rubber wire seal back into wire end of connector.

NOTE

Push the pin and socket halves of the connector

Repeat steps 3 and 4 as necessary until the desired result is

together until the latch “clicks.” The groove in the socket

achieved.

housing must be aligned with the tab in the pin housing.

Push on wire end of the lead to extract the terminal from

the mating end of the connector. See B in Figure 8-36.

If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

Assembly

NOTE

For wire color locations, see Section

8.8 WIRING DIA-

GRAMS and then refer to Figure 8-37.

1. Using a thin flat blade, like that on an X-Acto knife, care-

fully bend the tang outward away from the terminal body.

Figure 8-37. Fuel Injector Connector [84B/85B]

See C in Figure 8-36.

8-28

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System Fuse Block

Disassembly

1. Remove system fuses and relay(s) from fuse block.

2. Remove secondary locks as follows:

a. Insert end of small flat blade screwdriver under lip of

locking wedge and gently pry up secondary lock.

NOTE

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

secondary lock. See Figure 8-38.

Lip of

Locking Wedge

f2205x8x

3. Remove socket terminals as follows:

a. Looking into chamber at top of fuse block, note the

Figure 8-38. Remove Secondary Locks From Fuse Block

tang next to each socket terminal.

b. Using a thin flat blade, like that on an X-Acto knife,

gently push tang away from terminal, and then tug

on wire to back terminal out wire end of chamber.

4. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

Assembly

Install socket terminals as follows:

NOTE

See Section 8.8 WIRING DIAGRAMS, MAIN HARNESS, for

f2204x8x

wire colors and locations.

a. With the open side of the socket terminal facing the

1. Headlamp

Radio Power

tang, push lead into chamber at the wire end of the

2. Ignition

Accessory

fuse block. A click is heard when the terminal is

3. Lighting

Battery

properly engaged.

4. Instruments

10. Brake Light Relay

5. Brakes/Cruise

11. P&A

b. Gently tug on the wire to verify that the terminal is

6. Radio Memory

locked in place and will not back out of the chamber.

Figure 8-39. Fuse Block (FLTR, FLHTC/U)

Install secondary locks as follows:

a. With the locking wedges positioned above the tangs

in each chamber, slide flat side of secondary lock

Disassembly

into slot (between rows), and push down until it bot-

toms. See Figure 8-38.

Remove seat.

Install system fuses and relay(s) in fuse block.

1WARNING

Always disconnect the negative battery cable first. If the

480 METRI-PACK SERIES

positive cable should contact ground with the negative

cable installed, the resulting sparks may cause a battery

explosion, which could result in death or serious injury.

General

Unthread bolt and remove battery negative cable (black)

Use the following instructions to service the B+ connector.

from battery negative (-) terminal.

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8-29

HOME

With the tang on the same side as the square shaped

f2250x8x

opening in the mating end of the connector housing,

feed terminal into wire end of connector housing until it

“clicks” in place.

Verify that terminal will not back out of the chamber. A

slight tug on the cable will confirm that it is locked.

Rotate the hinged secondary lock inward until latches

fully engage tabs on both sides of connector housing.

Mate pin and socket halves of connector.

Install new anchored cable strap in lower hole on left

side of frame crossmember (in front of battery box).

Tighten cable strap to capture conduit of both accessory

connector and B+ connector approximately one inch

from connector housings. See Figure 8-41.

Place battery in battery box, terminal side forward.

B+ Connector

Figure 8-40. Remove Seat

Unthread bolt and remove battery positive cable (red)

from battery positive (+) terminal.

Using a T40 TORX drive head, loosen bolt to move lip of

hold-down clamp off edge of battery. Remove battery

from battery box.

Cut anchored cable strap to release accessory connec-

f2258x8x

tor and B+ connector from left side of frame crossmem-

ber (in front of battery box). See Figure 8-41.

Using small flat blade screwdriver, depress button on pin

housing (red wire) side of the connector and pull apart

the pin and socket halves. See A of Figure 8-41.

Bend back the latch slightly and free one side of second-

ary lock, then repeat the step to release the other side.

Rotate the secondary lock outward on hinge to access

terminal in chamber of connector housing. See B of Fig-

ure 8-41.

f2259x8x

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 between the tang and the chamber wall

until it stops. Pivot the end of the pin toward the terminal

body to depress the tang. Remove the pin and then pull

terminal out wire end of connector housing. See C of

Figure 8-41.

If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

f2260x8x

Assembly

1. Carefully bend the tang outward away from the terminal

Figure 8-41. Remove Socket Terminal

body.

8-30

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Assembly

1WARNING

NOTE

Always connect the positive battery cable first. If the

For wire location purposes, alpha characters are molded into

positive cable should contact ground with the negative

the secondary locks of each connector housing.

cable installed, the resulting sparks may cause a battery

explosion, which could result in death or serious injury.

Using a thin flat blade, like that on an X-Acto knife, care-

8. Insert bolt through battery positive cable

(red) into

fully bend the tang outward away from the terminal body.

threaded hole of battery positive (+) terminal. Tighten

With the tang facing the chamber wall, push the lead into

bolt to 60-96 in-lbs (6.8-10.9 Nm).

the chamber at the wire end of the connector. A click is

9. Insert bolt through battery negative cable (black) into

heard when the terminal is properly seated.

threaded hole of battery negative (-) terminal. Tighten

Gently tug on the wire end to verify that the terminal is

bolt to 60-96 in-lbs (6.8-10.9 Nm).

locked in place and will not back out of the chamber.

10. Rotate hold-down clamp so that the lip (with rubber pad)

rests on the edge of the battery. Using a T40 TORX drive

Rotate the hinged secondary lock inward until tabs fully

head, tighten the clamp bolt to 15-20 ft-lbs (20-27 Nm).

engage latches on both sides of connector.

11. Install seat.

Push the pin and socket halves of the connector

together until the latches “click.”

Install connector on barbed anchor or other retaining

device, if present.

630 METRI-PACK SERIES

General

800 METRI-PACK SERIES

Use these instructions to service the following connectors:

● Main to Interconnect Harness [15]

General

● Ignition Light/Key Switch [33]

Use the following instructions to service the maxi-fuse holder.

Disassembly

1. Remove connector from barbed anchor or other retain-

Disassembly

ing device, if present.

2. Bend back the external latch slightly and separate pin

1. Remove maxi-fuse.

and socket halves of the connector.

2. Remove socket terminals as follows:

3. Bend back the latch slightly and free one side of the sec-

ondary lock. Repeat the step to unlatch the other side.

a. Gently pull sides of secondary lock away from

socket housing to disengage slots from tabs on

4. Rotate the secondary lock outward on hinge to view the

socket housing. See A of Figure 8-42. Free second-

terminals in the chambers of the connector housing. The

ary lock from cables and set aside.

locking tang is on the side opposite the crimp tails and

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

b. Take note of the opening on one side of the socket

place.

terminal. Gently insert flat blade of pick (Snap-On

TT600-3) or small screwdriver into opening until it

5. Moving to the mating end of the connector, take note of

stops. Pivot the pick toward the terminal body and

the small opening on the chamber wall side of each ter-

hold in position. See B of Figure 8-42.

minal.

c. Tug on cable to pull socket from wire end of socket

6. Insert pick

(Snap-on® TT600-3) into opening until it

housing. A firm tug is necessary to overcome the

stops. Pivot the end of the pick toward the terminal to

resistance of the rubber seal.

depress the locking tang.

7. Remove the pick and gently tug on the wire to pull the

d. Repeat steps 2(b) and 2(c) to remove remaining

terminal from the wire end of the connector. Repeat

socket terminal.

steps if the terminal is still locked in place.

8. If necessary, crimp new terminals on wires. See Crimp-

3. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

2005 Touring: Wiring

8-31

HOME

d. Repeat steps

1(a) thru

1(c) to install remaining

f2245x8x

socket terminal.

e. Install secondary lock onto cables and then push

onto wire end of socket housing until slots engage

tabs on sides of socket housing.

Install maxi-fuse.

Tab

Secondary

PACKARD MICRO 64

Lock

General

f2244x8x

Use the following instructions to service the speedometer

and tachometer connectors.

Disassembly

1. Bend back the external latches slightly and separate the

pin and socket halves of the connector.

NOTE

To differentiate between the speedometer and tachometer

connectors, note that the speedometer connector has a sec-

ond length of conduit leading to the odometer reset switch.

Locate the head of the secondary lockpin on one side of

the connector housing. See Figure 8-44.

Insert the blade of a small screwdriver between the cen-

ter ear of the lockpin and the connector housing and

gently pry out lockpin. When partially removed, pull lock-

pin from connector housing.

Obtain the Packard Micro 64 Terminal Remover (HD-

45928). See Figure 8-43. Proceed as follows:

a. Locate small hole between terminals on mating end

of connector. See Figure 8-44.

f2246x8x

b. Push the adjacent terminals all the way into the con-

nector housing and then insert tool into hole until it

bottoms. See upper frame of Figure 8-45.

Figure 8-42. Remove Socket Terminals

Assembly

1. Install socket terminals as follows:

a. Carefully bend tang outward away from the terminal

body. See C of Figure 8-42.

b. Feed socket into wire end of socket housing until it

“clicks” in place. Verify that socket will not back out

of chamber. A slight tug on the cable will confirm

that it is locked.

Figure 8-43. Packard Micro 64 Terminal Remover

c. Push rubber seal into wire end of socket housing.

(Part No. HD-45928).

8-32

2005 Touring: Wiring

HOME

NOTE

Small

f2202x8x

For wire location purposes, the corners of the socket housing

Hole

are stamped with the numbers 1, 6, 7 and 12, representing

Secondary

terminals 1-6 on one side, and 7-12 on the other. See Figure

Lockpin

8-44.

Bottom the terminal in the chamber and then gently tug

on the wire to verify that it is locked in place.

NOTE

Once the terminal is removed it may not lock in place when

first reinstalled. Until the lock engages, move the terminal

back and forth slightly while wiggling the lead.

Figure 8-44. Mating End of Connector

3. Since the terminal remover tool releases two terminals

simultaneously, repeat step 2 on the adjacent terminal

even if it was not pulled from the connector housing.

4. With the center ear on the head of the secondary lockpin

facing the mating end of the connector, push lockpin in

until head is flush with the connector housing.

5. Push the pin and socket halves of the connector

together until the latches “click.”

Crimping Instructions

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

f2196x8x

Obtain the Packard Micro 64 Terminal Crimper (HD-

45929). See Figure 8-46.

Squeeze the handles to cycle the tool to the fully open

position.

Obtain new contact (socket terminal). Verify that contact

and crimp tails are not bent or deformed.

Raise locking bar and barrel holder by pushing up on

bottom tab with index finger. See Figure 8-47.

With the crimp tails facing upward, insert contact

through locking bar into front hole in barrel holder (20-22

gauge wire).

Release locking bar to lock position of contact. When

f2197x8x

correctly positioned, the locking bar fits snugly in the

space at the front of the core crimp tails and the closed

Figure 8-45. Insert Tool and Remove Terminal

side of the terminal rests on the outer nest of the crimp

tool. See Figure 8-48.

c. Leaving the tool installed, gently tug on wires to pull

either one or both terminals from wire end of con-

nector. See lower frame of Figure 8-45. Remove

tool.

If necessary, crimp new terminals on wires. See Crimp-

ing Instructions on this page.

Assembly

1. Insert terminal into its respective numbered chamber on

wire end of connector. No special orientation of the ter-

Figure 8-46. Packard Micro 64 Terminal Crimper

minal is necessary.

(Part No. HD-45929)

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HOME

11. Inspect the quality of the core and insulation crimps. Dis-

tortion should be minimal.

PACKARD 100W

General

Use the following instructions to service the ECM connector.

f2198x8x

Figure 8-47. Raise Locking Bar and Barrel Holder

Disassembly

Gently depress latch on each side of the clear plastic

f2199x8x

secondary lock and remove. For best results, release

one side at a time, See Figure 8-50.

Carefully cut cable strap to free strain relief collar from

conduit.

Using a thin blade, gently pry at seam at back of socket

housing to release three plastic pins from slots in hous-

ing. Separate and spread halves of socket housing. See

Figure 8-51.

Push on selected wire to free terminal from chamber.

See Figure 8-52.

Locking

Barrel

If necessary, crimp new terminals on wires. See Crimp-

Bar

Holder

ing Instructions on the next page.

Figure 8-48. Position Contact in Crimper

f2062x8x

f2201x8x

Figure 8-49. Crimp Terminal Onto Wire

Insert wires between crimp tails until ends make contact

with locking bar. Verify that wire is positioned so that

wide pair of crimp tails squeeze bare wire strands, while

the narrow pair folds over the insulation material.

1. Latch

Squeeze handle of crimp tool until tightly closed. Tool

2. Rib

Conduit

automatically opens when the crimping sequence is

3. Secondary Lock

Cable Strap

complete. See Figure 8-49.

4. Strain Relief Collar

External Latch

10. Raise locking bar and barrel holder to remove contact.

Figure 8-50. Remove Secondary Lock

8-34

2005 Touring: Wiring

HOME

Crimping Instructions

Strip wire lead removing 5/32 inch (4.0 mm) of insula-

tion.

Compress handles until ratchet automatically opens.

NOTE

Pins

Always perform core crimp before insulation/seal crimp.

See Figure 8-53. Determine the correct dye or nest for

the core crimp.

Position the core crimp on the appropriate nest. Be sure

the core crimp tails are facing the forming jaws.

Gently apply pressure to handles of tool until crimpers

just secure the core crimp tails.

f2063x8x

Insert stripped wire between crimp tails. Verify that wire

is positioned so that short pair of crimp tails squeeze

Figure 8-51. Separate Halves of Socket Housing

bare wire strands, while long pair is positioned over the

insulation or seal material.

Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is

complete.

See Figure 8-53. Determine the correct dye or nest for

the insulation/seal crimp.

Packard Terminal Crimp Dyes (Nests)

Packard 270

Packard 271

Packard 115

(HD-38125-6)

(HD-38125-7)

(HD-38125-8)

f2064x8x

Figure 8-52. Push Wire to Extract Terminal

Assembly

1. From inside socket housing, gently pull on wire to draw

terminal into chamber. See Figure 8-52.

2. Exercising caution to avoid pinching wires, press halves

Sealed

Non-Sealed

of socket housing together until three plastic pins fully

Terminals

engage slots in housing. See Figure 8-51.

1-5

A-E

F-G

3. Install new cable strap in groove of strain relief collar

capturing cable conduit. See Figure 8-50.

Butt Splices*

4. With the two ribs on the secondary lock on the same

*See Appendix 8.6 SEALED BUTT SPLICE CONNECTORS.

side as the external latch, install over terminals until

latches lock in place.

Figure 8-53.

Packard Terminal

Crimp Tools

2005 Touring: Wiring

8-35

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Harley Davidson 2005 touring models. Service repair manual — page 59

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