Harley Davidson 2008 Sportster Models. Electrical Diagnostics Manual — page 15

AMP MULTILOCK CONNECTORS

A.2

AMP MULTILOCK CONNECTOR REPAIR

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PART NUMBER

TOOL NAME

HD-41609

AMP MULTILOCK CRIMPER

General

AMP Multilock connectors are found between wire harnesses

and component wiring and may be either floating or anchored

to the frame with attachment clips.

See Figure A-3. 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 MULTILOCK

CRIMPER (Part No. HD-41609).

Separating Pin and Socket Housings

1. If necessary, slide connector attachment clip T-stud to the

1. Attachment clip

large end of the opening.

2. Release button

3. Socket housing

2. See Figure A-3. Depress the release button (2) on the

4. Pin housing

socket terminal side of the connector and pull the socket

housing (3) out of the pin housing (4).

Figure A-3. AMP Multilock Connector

Mating Pin and Socket Housings

1. Hold the housings to match wire color to wire color.

Removing Terminals from Housing

2. Insert the socket housing into the pin housing until it snaps

1. See Figure A-4. Bend back the latch (1) to free one end

in place.

of secondary lock (2) then repeat on the opposite end.

Hinge the secondary lock outward.

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-

2. Look in the terminal side of the connector (opposite the

stud to small end of opening.

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. 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.

2008 Sportster Diagnostics: Appendix A Connector Repair A-3

NOTES

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•

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.

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- AMP

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-4. AMP Multilock Connector: Socket and Pin

Housings

3-place housing

Inserting Terminals into Housing

6-place housing

10-place housing

NOTE

Figure A-5. AMP Multilock Connector: Cavity Numbers on

See Figure A-5. Cavity numbers are stamped into the sec-

Secondary Locks (Socket Housings Shown)

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

Preparing Wire Leads for Crimping

chamber. Insert the terminal into its numbered cavity until

1. Strip

5/32 in. (4.0 mm) of insulation from the wire lead.

it snaps in place.

A-4 2008 Sportster Diagnostics: Appendix A Connector Repair

2. See Figure A-4 and Figure A-7. Select the pin/socket ter-

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minals 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-1.

Table A-1. AMP Multilock Connector: Crimp Tool Wire

Gauge/Nest

WIRE GAUGE

NEST

Front

Middle

Rear

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-6. AMP Multilock Connector: Socket and Pin

Housings

2008 Sportster Diagnostics: Appendix A Connector Repair A-5

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1. Insulation crimp tail

2. Wire crimp tail

3. Locking bar groove

Figure A-7. AMP Multilock Connector: Socket Terminal

Crimping Terminals to Leads

NOTE

Crimping with an Amp Multilock tool is a one step operation.

One squeeze crimps both the wire core and the insulation tails.

1. See Figure A-8. Squeeze the handles to cycle the AMP

MULTILOCK CRIMPER (Part No. HD-41609) to the fully

open position (1).

2. Raise locking bar by pushing up on bottom flange (2).

NOTE

See Figure A-4 and Figure A-7. 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 Figure A-8. 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

Open position

squeeze bare wire strands, while insulation crimp tails fold

Locking bar flange

over the wire lead insulation.

Insert contact

Release locking bar

7. Squeeze handle of crimp tool until tightly closed. Tool

Insert lead

automatically opens when the crimping sequence is com-

Squeeze

plete.

Raise locking bar

8. Raise up locking bar (8) and remove crimped terminal.

Remove crimped terminal

Figure A-8. AMP Multilock Connector: Terminal Crimping

Procedure

Inspecting Crimped Terminals

See Figure A-9. Inspect the wire core crimp (2) and insulation

crimp (1). Distortion should be minimal.

A-6 2008 Sportster Diagnostics: Appendix A Connector Repair

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1. Insulation crimp

2. Wire core crimp

Figure A-9. AMP Multilock Connector: Terminal Crimp

2008 Sportster Diagnostics: Appendix A Connector Repair A-7

DELPHI CONNECTORS

A.3

DELPHI CONNECTOR REPAIR

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General

Delphi connectors are embossed with the brand name, Delphi,

on the housing latch.

Separating Pin and Socket Housings

See Figure A-10. Bend back the external latch(es) slightly and

separate pin and socket halves of connector.

Mating Pin and Socket Housings

Push pin and socket halves of connector together until external

latch(es) engage.

Removing Socket Terminals

NOTE

Although the parts of the different Delphi connectors vary in

appearance, the instructions which follow will work for all. The

only exception is the oil pressure sender connector [139B], the

terminals of which are removed like the Packard push-to-seat

connectors. Therefore, see A.10 150 METRI-PACK CON-

NECTORS to remove/install terminals in this connector.

1. See Figure A-11. If present, free one side of wire lock (1)

Figure A-10. Delphi Connector: Socket Housing Latch

from ear on wire end of socket housing, then release the

other side. Release wires from channels in wire lock and

remove from socket housing.

2. Use a fingernail to pry colored terminal lock (2) loose and

then remove from mating end of socket housing.

3. Using a thin flat blade, like the unsharpened edge of a

hobby knife, gently pry tang (3) outward away from ter-

minal, and then tug on wire to back terminal out wire end

of chamber. Do not pull on wire until tang is released or

terminal will be difficult to remove.

Installing Socket Terminals

NOTE

For wire location purposes, alpha or numeric characters are

stamped into the wire end of each socket housing.

1. Gently push tang on socket housing inward toward

chamber. With the open side of the terminal facing the

tang, push terminal into chamber at wire end of socket

housing.

2. Gently tug on wire to verify that terminal is locked and will

not back out of chamber. If necessary, use fingernail to

push tang into engagement with terminal.

3. Install colored terminal lock onto mating end of socket

housing.

4. If present, seat wires in separate channels of wire lock

and then push channels inside chambers at wire end of

socket housing. Fully installed, slot on each side of wire

lock engages ear on socket housing.

A-8 2008 Sportster Diagnostics: Appendix A Connector Repair

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1. Remove wire lock

2. Remove terminal lock

3. Pry tang outward

Figure A-11. Delphi Connector: Removing Socket

Terminals

2008 Sportster Diagnostics: Appendix A Connector Repair A-9

DEUTSCH1-PLACE ELECTRICAL CONNECTORS

A.4

DEUTSCH 1-PLACE CONNECTOR REPAIR

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Separating Pin and Socket Housings

Depress external latch and separate the pin and socket hous-

ings of the Deutsch one place connector found on voltage

regulators.

Mating Pin and Socket Housings

Orient the housings so the latch faces the catch and push the

housings together until it clicks.

Removing Socket Terminals

NOTE

Rough handling or careless storage can result in tool damage.

Exercise care to avoid cracking or breaking the thin plastic

construction.

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

voltage regulator cable to move out of the way.

2. See Figure A-12. Using terminal pick tool (Deutsch®

114008) (1), install tool onto voltage regulator cable so

that the tapered end is in the wire end of the housing (2).

3. Push tool into wire end of housing until it bottoms. Gently

tug on housing to pull from terminal (3).

4. Remove tool from voltage regulator cable.

Installing Socket Terminals

1. 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.

2. Fit rear wire seal into back of housing.

1. Deutsch terminal pick tool (114008)

2. Tool installed in housing

3. Terminal removed from housing

Figure A-12. Deutsch 1-Place Connector: Remove

Socket/Pin Housing

A-10 2008 Sportster Diagnostics: Appendix A Connector Repair

DEUSCH ELECTRICAL CONNECTORS

A.5

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

DEUTSCH CONNECTOR REPAIR

frame. Push assembly forward to engage small end of

PART NUMBER

TOOL NAME

slot.

HD-41475

DEUTSCH CONNECTOR SERVICE

KIT

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HD-41475-100

FLAT BLADE L-HOOK

General

Deutsch connectors are colored coded for location purposes.

Those connectors associated with left side accessories, such

as the front and rear left turn signals, are gray. All other con-

nectors, including those associated with right side accessories,

are black.

NOTE

A DEUTSCH CONNECTOR SERVICE KIT (Part No. HD-

41475) contains a selection of wire seals, internal seals, seal

plugs, secondary locking wedges, attachment clips and

socket/pin terminals. Also included is a compartmented storage

box, carrying case and a FLAT BLADE L-HOOK (Part No. HD-

41475-100) is used for the removal of all types of locking

wedges.

Separating Pin and Socket Housings

See Figure A-12. To separate the connector halves, depress

1. External latch

the external latch(es) (1) on the socket housing (2) while

2. Socket housing

rocking the pin (3) and socket housings.

3. Pin housing

NOTES

Figure A-13. Deutsch Connector

•

Generally, the socket housing is found on the accessory

side, while the pin housing is plumbed to the wiring har-

Removing Socket Terminals

ness.

1. See Figure A-14. Insert a small screwdriver between the

•

Two-, three-, four- and six-place Deutsch connectors have

socket housing and locking wedge in-line with the groove

one latch on the connector.

(in-line with the pin holes if the groove is absent). Turn the

•

Eight- and twelve-place connectors have a latch on each

screwdriver 90 degrees to pop the wedge up and remove

side. Simultaneously press both latches to separate the

the secondary locking wedge.

connector.

2. See Figure A-17. Use a pick or small screwdriver to

Mating Pin and Socket Housings

depress terminal latches inside socket housing and back

out sockets through holes in rear wire seal.

1. Align the connectors to match the wire lead colors.

a. For One External Latch: Two-, three-, four- and six-

NOTE

place Deutsch connectors have one external latch on

If wire leads require new terminals, see the instructions for

the socket half of the connector. To fit the halves of

crimping terminals.

the connector together, the latch on the socket side

must be aligned with the latch cover on the pin side.

Installing Socket Terminals

b. For Two External Latches: (8-place and 12-place)

1. Match wire lead color to connector cavity.

Align the tabs on the socket housing with the grooves

2. See Figure A-16. Fit rear wire seal (1) into back of socket

on the pin housing.

housing (2), if removed.

2. Insert socket housing into pin housing until it snaps or

3. Grasp wire lead (3) approximately

1.0 in. (25.4 mm)

clicks into place.

behind the socket terminal. Gently push socket through

For Two External Latches: (8-place and 12-place) If

hole in wire seal into its chambers until it "clicks" in place.

latches do not click (latch), press on one side of the con-

4. A tug on the wire will confirm that it is properly locked in

nector until that latch engages, then press on the opposite

place.

side to engage the other latch.

NOTE

3. If necessary, fit the attachment clip to the pin housing.

Seal plugs (6) are installed through the wire seals of unused

chambers. If removed, seal plugs must be replaced to seal the

connector.

2008 Sportster Diagnostics: Appendix A Connector Repair A-11

5. Install internal seal (4) on lip of socket housing, if removed.

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6. Insert tapered end of secondary locking wedge (5) into

socket housing and press down until it snaps in place. The

wedge fits into the center groove within the socket housing

and holds the terminal latches tightly closed.

NOTES

•

See Figure A-15. While rectangular wedges do not require

a special orientation, the conical secondary locking wedge

of the 3-place connector must be installed with the arrow

(1) pointing toward the external latch.

•

If the secondary locking wedge does not slide into the

installed position easily, verify that all terminals are fully

installed in the socket housing. The lock indicates when

terminals are not properly installed by not entering its fully

installed position.

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1. Arrow on socket locking wedge

2. Arrow on pin locking wedge

Figure A-15. Deutsch Connector: 3-Place Locking Wedges

Figure A-14. Deutsch Connector: Remove Secondary

Locking Wedge

A-12 2008 Sportster Diagnostics: Appendix A Connector Repair

gray connectors, plugs or receptacles must be replaced

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by those of the same color.

•

When replacing both socket and pin housings, then the

black may be substituted for the gray, and vice versa. The

socket and pin housings of all other connectors are inter-

changeable, that is, the black may be mated with the gray,

since the alignment tabs are absent and the orientation

of the external latch is the same.

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Figure A-17. Deutsch Connector: Depress Terminal Latch

and Back Out Pin

Installing Pin Terminals

1. Wire seal

1. See Figure A-18. Fit wire seal (1) into back of pin housing

2. Socket housing

(2).

3. Wire lead

2. Grasp wire lead approximately 1.0 in. (25.4 mm) behind

4. Internal seal

the pin terminal (3). Gently push pin through holes in wire

5. Secondary locking wedge

seal into its respective numbered chamber until it "clicks"

6. Seal plug

in place.

Figure A-16. Deutsch Connector: 2, 3, 4 and 12-Place

NOTE

Socket Housings

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

Removing Pin Terminals

pin housing and press down until it snaps in place.

1. Use the hooked end of a stiff piece of mechanics wire, a

NOTES

needle nose pliers or the FLAT BLADE L-HOOK (Part

•

The wedge fits in the center groove of the pin housing and

No. HD-41475-100) to remove the secondary locking

holds the terminal latches tightly closed.

wedge.

•

See Figure A-15. While rectangular wedges do not require

2. Gently depress terminal latches inside pin housing and

a special orientation, the conical secondary locking wedge

back out pins through holes in wire seal.

of the 3-place connector must be installed with the arrow

(2) pointing toward the external latch.

NOTES

•

If wire leads require new terminals, see the instructions

•

If the secondary locking wedge does not slide into the

for crimping terminals.

installed position easily, verify that all terminals are fully

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

•

If it should become necessary to replace a pin or socket

minals are not properly installed by not entering its fully

housing, please note that the 8-place and 12-place gray

installed position.

and black connectors are not interchangeable. Since loc-

ation of the alignment tabs differ between the black and

2008 Sportster Diagnostics: Appendix A Connector Repair A-13

Crimping Terminals

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Identify which of the types of Deutsch terminals are used with

the connector and follow the corresponding crimping instruc-

tions. Refer to Table A-2.

1. Wire seal

2. Pin housing

3. Pin terminal

4. Locking wedge

Figure A-18. Deutsch Connector: 2, 3, 4 and 12-Place Pin

Housings

Table A-2. Deutsch Connector: Terminal Crimping Instructions

TYPE

CRIMPING INSTRUCTIONS

Standard (with crimp tails)

A.6 DEUTSCH STANDARD TERMINALS

Mini

Terminal (solid barrel)

A.8 DEUTSCH SOLID BARREL TERMINALS

Mini

Terminal (with crimp tails)

A.7 DEUTSCH MINI-TERMINAL CRIMPS

A-14 2008 Sportster Diagnostics: Appendix A Connector Repair

DEUTSCH STANDARD TERMINALS

A.6

straight upward. When positioned, the locking bar fits snugly

DEUTSCH STANDARD TERMINAL CRIMPS

in the space between the contact band and the core crimp tails.

PART NUMBER

TOOL NAME

4. Insert stripped wire core between crimp tails until ends

HD-39965-A

DEUTSCH TERMINAL CRIMP TOOL

make contact with locking bar. Verify that wire is positioned

so that short pair of crimp tails squeeze bare wire strands,

Preparing Wire Leads for Crimping

while long pair folds over the insulation.

1. Use a shop gauge to determine gauge of wire lead.

5. Squeeze handle of crimp tool until tightly closed. Tool

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

automatically opens after the terminal is crimped.

6. Raise locking bar up and remove wire lead and terminal.

Crimping Terminal to Lead

1. See Figure A-19. Squeeze the handles of the DEUTSCH

Inspecting Crimps

TERMINAL CRIMP TOOL (Part No. HD-39965-A) to open

Inspect the wire core and insulation crimps. Distortion should

the jaws. Push the locking bar (1) up.

be minimal.

2. Insert (2) terminal (socket/pin) through hole of the locking

bar, so that the rounded side of the contact barrel rests in

Table A-3. Deutsch Standard Terminal Crimp: Wire Gauge

the nest (concave split level area) with the crimp tails

To Die

facing upward. To match the wire gauge to the crimp tool

WIRE GAUGE (AWG)

CRIMP TOOL DIE

die, refer to Table A-3.

Front

3. Release locking bar to lock terminal in die.

16-18

Middle

NOTE

If the crimp tails are slightly out of vertical alignment, the crimp

tool automatically rotates the terminal so that the tails face

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1. Open jaws and raise locking bar

4. Insert stripped lead

2. Insert terminal in locking bar

5. Squeeze crimper

3. Release locking bar to lock terminal in die

6. Raise locking bar and remove terminal

Figure A-19. Crimping a Deutsch Standard Terminal

2008 Sportster Diagnostics: Appendix A Connector Repair A-15

DEUTSCH MINI-TERMINAL CRIMPS

A.7

DEUTSCH MINI TERMINAL CRIMPS

Inspecting Crimps

Inspect the core and insulation crimps. Distortion should be

PART NUMBER

TOOL NAME

minimal.

HD-38125-7

PACKARD TERMINAL CRIMPER

Preparing Wire Leads for Crimping

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

Crimping a Mini Terminal to Wire Lead

1. See Figure A-20. Compress the handles of PACKARD

TERMINAL CRIMPER (Part No. HD-38125-7) until the

ratchet (2) automatically opens.

NOTE

Always perform core crimp before insulation crimp.

2. Position the core crimp on die E (1) of the crimper. Be

sure the core crimp tails are facing the forming jaws.

3. Gently apply pressure to handles of tool until crimpers just

secure the core crimp tails.

4. Insert stripped wire core stands between crimp tails. Pos-

ition wire so that short pair of crimp tails squeeze bare

wire strands, while long pair squeeze over the insulation.

5. Squeeze handle of crimper until tightly closed. Tool auto-

matically opens when the crimping sequence is complete.

NOTE

If the crimper does not open, it can be opened by squeezing

the ratchet trigger (2).

6. Position the insulation crimp on nest C of the crimper. Be

sure the insulation crimp tails are facing the forming jaws.

7. Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is com-

E die

plete.

Crimper ratchet trigger

Figure A-20. Packard Terminal Crimper (HD-38125-7)

A-16 2008 Sportster Diagnostics: Appendix A Connector Repair

DEUTSCH SOLID BARREL

TERMINALS

A.8

DEUTSCH SOLID BARREL TERMINAL

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CRIMPS

PART NUMBER

TOOL NAME

HD-42879

ELECTRICAL CRIMPER TOOL

Preparing Wire Leads For Crimping

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

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

Adjusting Crimper Tool

1. See Figure A-21. Squeeze the ELECTRICAL CRIMPER

TOOL (Part No. HD-42879) handles to cycle the crimp

tool to open.

2. Remove locking pin (1) from selector knob (2).

3. Raise selector knob and rotate until selected wire size

stamped on wheel is aligned with "SEL. NO." arrow (3).

4. Loosen knurled locknut (4) and turn adjusting screw (5)

clockwise (in) until it stops.

Crimping a Barrel Contact To Wire Lead

1. See Figure A-22. 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

Locking pin

sequence is complete.

Selector knob

SEL. NO. arrow

5. Remove wire lead with crimped contact from indentor.

Knurled locknut

NOTE

Adjusting screw

Tool must be readjusted when changing contact size/type.

Figure A-21. Electrical Crimper Tool (HD-42879)

6. Install pin to lock selector knob.

Inspecting Crimps

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

the barrel.

2008 Sportster Diagnostics: Appendix A Connector Repair A-17

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1. Contact barrel

2. Indentor cover

3. Indentor point

4. Stripped wire lead

Figure A-22. Deutsch Solid Barrel

A-18 2008 Sportster Diagnostics: Appendix A Connector Repair

RELAY AND FUSE BLOCKS

A.9

FUSE BLOCK REPAIR

NOTE

The wiring diagram indicates when one socket terminal is be

Removing Socket Terminals

crimped to two wire leads.

1. See Figure A-23. To remove secondary locks, insert end

of small flat blade screwdriver (1) under lip of locking

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wedge (2) and gently pry up secondary lock.

NOTE

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

secondary lock.

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

next to each socket terminal.

3. Using a thin flat blade, like that on a hobby knife, gently

push tang away from terminal, and then tug on wire to

back terminal out.

Installing Socket Terminals

1. Match the wire lead color to the fuse block terminal cavity.

NOTES

•

Refer to the main harness wiring diagram for wire lead

1. Pry up secondary lock

color codes.

2. Lip of locking wedge

•

See Figure A-24. The main fuse block terminal cavity is

Figure A-23. Fuse Block: Remove Secondary Locks

identified as alpha (1) and numeric (2) coordinates. Refer

to the main harness wiring diagram for fuse block terminal

cavity coordinates.

2. With the open side of the socket terminal facing the tang,

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push lead into chamber at the wire end of the fuse block.

A click is heard when the terminal is properly engaged.

3. Gently tug on the wire to verify that the terminal is locked

in place and will not back out of the chamber.

4. Install the secondary locks. With the locking wedges

positioned above the tangs in each chamber, slide flat

side of secondary lock into slot (between rows), and push

down until it bottoms.

Crimping Terminals

Terminals are crimped twice; once over the wire core and a

second time over the insulation/seal.

A correctly crimped terminal may require different crimping

dies found on separate crimpers.

1. Alpha

2. Numeric

Figure A-24. Fuse Block: Coordinates (typical)

2008 Sportster Diagnostics: Appendix A Connector Repair A-19

150 METRI-PACK CONNECTORS

A.10

150 METRI-PACK CONNECTOR REPAIR

Inserting Socket Terminal

General

NOTE

For wire location purposes, alpha characters are stamped into

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

the socket housings.

There are two types of connectors in this series:

See Figure A-25 for pull-to-seat connector or Figure A-26

•

Pull-to-Seat

for push to seat connector. Using a thin flat blade, like that

on a hobby knife, carefully bend the tang outward away

•

Push-to-Seat

from the terminal body.

Separating Pin and Socket Housings

Gently pull or push on the lead to install the terminal back

Bend back the external latch slightly and separate the pin and

into the chamber. A click is heard when the terminal is

socket halves of the connector.

properly seated.

Mating Pin and Socket Housings

Gently pull or push on the lead to verify that the terminal

is locked in place.

Align the wire colors and push the pin and socket halves of the

connector together.

For push-to-seat: See Figure A-26. Seat wires in separate

channels of wire lock and then push channels inside

Removing Socket Terminal

chambers at wire end of socket housing. Fully installed,

slot on each side of wire lock engages ear on socket

1. See Figure A-25 for pull-to-seat connector or Figure A-26

housing.

for push to seat connector. Remove wire lock (1) from wire

end of socket housing on push-to-seat type connectors.

NOTE

For best results, free one side of wire lock first and then release

the other side.

2. Find the locking tang in the mating end of the connector.

NOTE

The tangs are always positioned in the middle of the chamber

and are on the same side as the external latch.

3. Gently insert a safety pin into the chamber about

1/8

in. (3.2 mm).

a. For pull-to-seat: Stay between the terminal and the

chamber wall and pivot the end of the pin toward the

terminal body.

b. For push-to-seat: There is a small opening for the

pin.

4. When a click is heard, remove the pin and repeat the

procedure.

NOTE

The click is the sound of the tang returning to the locked posi-

tion as it slips from the point of the pin.

5. Pick at the tang until the clicking stops and the pin seems

to slide in deeper than it had previously. This is an indica-

tion that the tang has been depressed.

NOTE

On those terminals that have been extracted on multiple

occasions, the click may not be heard, but pivot the pin as if

the click was heard at least 3 times.

6. Remove the pin.

a. For pull-to-seat: Push on the lead to extract the ter-

minal from the mating end of the connector.

b. For push-to-seat: Pull on the lead to draw the ter-

minal out the wire end.

A-20 2008 Sportster Diagnostics: Appendix A Connector Repair

sm00027

sm00028

1. Remove wire lock

1. Locate tang in chamber

2. Pivot pin to depress tang

3. Pull to remove

3. Push to remove

4. Raise tang to install

Figure A-26. 150 Metri-Pack Connector: Push-to-Seat

Figure A-25. 150 Metri-Pack Connector: Pull-to-Seat

2008 Sportster Diagnostics: Appendix A Connector Repair A-21

280 METRI-PACK CONNECTORS

A.11

280 METRI-PACK CONNECTOR REPAIR

sm00029

General

See Figure A-27. Called Packard connectors, Metri-Pack series

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

Separating Pin and Socket Housings

Depress the wireform and use a rocking motion to detach the

socket connector half.

Mating Pin and Socket Housings

Align the groove in the socket housing with the tab in the pin

housing. Push the pin and socket halves of the connector

together until the latch clicks.

Removing Socket Terminals

1. See Figure A-28. Pry rubber seal from wire end of con-

nector and move seal down wires (1) toward conduit. Hold

the connector so that the wireform is facing down.

2. Looking into the wire end of the connector, insert the point

of a safety pin (2) between the top of the terminal and the

inside chamber wall.

Figure A-27. 280 Metri-Pack Connector (P.E.D.)

3. Push safety pin completely into chamber while watching

terminal on mating end of connector. When terminal is

observed moving forward slightly, tang is depressed.

Remove safety pin.

NOTE

Repeat as necessary until the terminal can be pushed out of

the connector.

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

the mating end of the connector.

5. If necessary, crimp new terminals on wires. See

A.15 METRI-PACK TERMINALS, Metri-Pack Terminal

Crimps.

Installing Socket Terminals

NOTE

Terminal cavities are lettered on the socket housing. To match

the wire lead colors to the terminal cavity, refer to the wiring

diagram.

1. See Figure A-28. Using a thin flat blade, like an X-Acto

knife (4), carefully bend the tang outward away from the

terminal body.

2. Gently pull on the wire lead (5) to draw the terminal back

into the chamber. The tang faces opposite the wireform

as it enters the chamber.

NOTE

A "click" is heard when the terminal is properly seated.

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

4. Fit rubber wire seal back into wire end of connector.

Crimping Terminals

If necessary, crimp new terminals on the wire leads. Refer to

A.15 METRI-PACK TERMINALS, Metri-Pack Terminal Crimps.

A-22 2008 Sportster Diagnostics: Appendix A Connector Repair

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