Harley Davidson 2018 softail models. Service manual — page 50
1
Secondary lock
2
Terminal extractor
3
Retention beam
Figure 2. Terminal Removal
Installing Terminal
1. See Figure 3. Align the open side of the crimp to the tang side of the connector cavity.
2. Install the terminal into the connector. Terminal will snap into place.
3. Install secondary lock into the connector.
Figure 3. Socket Terminal Orientation: Crimp Open Side
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools
Description
Part Number
Qty.
TERMINAL EXTRACTOR
B-50085
1
DIE SET
HD-50120-11
1
HAND CRIMP FRAME
HD-50120-2
1
NOTE
Use HAND CRIMP FRAME (Part Number:HD-50120-2) with DIE SET (Part Number:HD-50120-11) for Tyco MCON
series terminal crimping. Refer to Bosch tool instruction sheet for crimping instructions.
Separating Connector
See Figure 1. Pull the safety lock up, press the safety lock to the connector and release, pull and separate the two
halves.
1
Pull safety lock
2
Press safety lock
3
Pull and separate connector
Figure 1. Separating Connector
Mating Connector
See Figure 2. Push the halves of connector together, listen for click of the safety lock, then push the safety lock down.
1
Push connectors together
2
Listen for click
3
Push safety lock down
Figure 2. Mating Connector
Terminal Removal
1. See Figure 3. Using a screwdriver, release the secondary lock.
2. Insert TERMINAL EXTRACTOR (Part Number:B-50085) into primary lock.
3. The terminal can be removed by pulling on the wire while simultaneously applying slight press to disengage the
primary lock.
1
Secondary lock in locked position
2
Secondary lock in unlocked position
3
Primary lock
4
Removal tool
5
Remove terminal
Figure 3. Removing Terminal
Installing Terminals
NOTE
Proper orientation of terminal required.
1. See Figure 4. Insert terminals into connector until an audible click is heard or lock is felt.
2. Push secondary lock into locked position.
1
Terminal
2
Primary lock
3
Secondary lock in unlocked position
4
Secondary lock in locked position
Figure 4. Inserting Terminal
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools
Description
Part Number
Qty.
TERMINAL EXTRACTOR
B-50085
1
SNAP-ON TERMINAL PICK
GA500A
1
HAND CRIMP FRAME
HD-50120-2
1
TYCO MCP DIE
HD-50120-8
1
The Tyco MCP sealed connector is used on certain ABS modules.
NOTE
Use HAND CRIMP FRAME (Part Number:HD-50120-2) with TYCO MCP DIE (Part Number:HD-50120-8) for Tyco
MCP series terminal crimping. Refer to Bosch tool instruction sheet for crimping instructions.
Separating Connector
See Figure 1. Press and hold the lock tab. Pulling on both ends of the lever, open the lever.
Figure 1. Tyco MCP Connector Release Bar
Mating Connector
Gently mate the pins to the socket. Press and hold the lock tab. Pressing on both ends of the lever, close the lever.
Terminal Removal (Large Terminals)
1. Snap the wire harness cover off of the back of the connector
NOTE
Insert a thin flat bladed screwdriver all the way to the bottom behind the tab of the secondary lock.
2. See Figure 2. Gently slide the secondary lock out of the connector with a screwdriver.
3. Insert the smallest pins of the SNAP-ON TERMINAL PICK (Part Number:GA500A) into the gaps on each side
of the terminal to compress the tangs on each side of the terminal.
4. Gently pull on the wire to remove the terminal.
1
Secondary lock
2
Terminal pick
Figure 2. Removing Small Socket Terminals
Terminal Removal (Small Terminals)
1. Snap the wire harness cover off of the back of the connector
NOTE
Insert a thin flat bladed screwdriver all the way to the bottom behind the tab of the secondary lock.
2. Gently slide the secondary lock out of the connector with a screwdriver.
3. See Figure 3. Insert the TERMINAL EXTRACTOR (Part Number:B-50085) into the cavity on the outside of
the terminal.
4. Tilt extractor to lift the latch and release the terminal.
5. Gently pull on the wire to remove the terminal.
1
Secondary lock
2
Terminal extractor
Figure 3. Removing Small Socket Terminals
Installing Terminals
1. Locate the wire lead cavity by number.
2. Use a hobby knife to bend the tangs on each side of the terminal outward.
3. Align the terminal.
4. Push the terminal in until it clicks.
5. Press the secondary lock back into the connector.
6. Snap the wire cover in place.
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools
Description
Part Number
Qty.
TERMINAL EXTRACTOR
B-50085
1
AMP MULTILOCK CRIMPER
HD-41609
1
MULTI-LOCK CRIMPER
HD-44695-A
1
Tyco Multilock Unsealed connectors are found between wire harnesses and component wiring. They are either floating or
anchored to the frame with attachment clips. To maintain serviceability, always return connectors to OEM locations after
service.
NOTE
Use the AMP MULTILOCK CRIMPER (Part Number:HD-41609) for 070 Multilock terminal crimping.
Use the MULTI-LOCK CRIMPER (Part Number:HD-44695-A) for 040 Multilock terminal crimping.
Refer to Bosch tool instruction sheet for crimping instructions.
Separating Connector
1. If necessary, slide connector attachment clip so T-stud is in the large end of the clip opening. Remove
connector from T-stud.
2. See Figure 1. Press the release button and pull the connector halves apart.
Mating Connector
1. Hold the connectors to match wire color to wire color.
2. Align the terminals and press the connectors together until they click in place.
3. If OEM location is a T-stud, fit large opening end of attachment clip over T-stud. Slide connector to engage T-
stud to small end of opening in clip.
1
Socket housing
2
Release button
3
Pin housing
4
Attachment clip
Figure 1. Tyco Multilock Unsealed Connector
Terminal Removal
1. See Figure 2. Bend back the latch to free one end of secondary lock 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. Using TERMINAL EXTRACTOR (Part Number:B-50085), press the tang in the housing to release the
terminal.
a. Socket: Lift the socket tang up.
b. Pin: Press the pin tang down.
NOTE
If the tang is released, a click is heard.
4. Gently pull on wire to remove terminal from cavity.
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 2. Tyco 070 Multilock Unsealed Connector: Socket and Pin Housings
Installing Terminals
NOTE
Match the wire color to the cavity number found on the wiring diagram.
The release button is always on the top of the connector.
On the pin side of the connector, tangs are positioned at the bottom of each cavity. Therefore, 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. Therefore, the socket terminal slot (on the same side
as the crimp tails) must face upward.
1. Hold the terminal so the catch faces the tang in the cavity. Insert the terminal into its numbered cavity until it
snaps in place.
2. Gently tug on wire ends to verify that all terminals are locked.
3. Rotate the hinged secondary lock inward until tabs are fully engaged on both sides of connector.
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools
Description
Part Number
Qty.
TERMINAL EXTRACTOR
B-50085
1
Separating Connector
1. Lift locking tab.
2. Pull the connector apart.
Mating Connector
1. Align the connector housings.
2. Press the housings together until the locking tab snaps into place.
Terminal Removal
1. File the edge of a TERMINAL EXTRACTOR (Part Number:B-50085) to a 45 degree angle.
2. See Figure 1. Remove seal from connector.
3. Lift locking tab on either side of connector and remove secondary lock.
4. Insert the extractor into the cavity next to the terminal. Press the retainer away from the terminal.
5. Gently pull the wire to remove the terminal from the connector.
Installing Terminal
1. Align terminal to the connector.
2. Install the terminal into the connector until it snaps into place.
3. Gently pull wire to verify terminal is locked.
4. See Figure 1. Install secondary lock into connector.
5. Install seal.
1
Terminal
2
Connector
3
Secondary lock
4
Seal
Figure 1. Tyco SuperSeal 1.5 Sealed Connector
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Refer to the table below for a list of common acronyms and abbreviations.
Table 1. Acronyms and Abbreviations
ACRONYM OR ABBREVIATION
DESCRIPTION
A
Amperes
AAT
Ambient air temperature
ABS
Anti-lock braking system
AC
Alternating current
ACC
Accessory position on ignition switch
ACR
Automatic compression release
AGM
Absorbed glass mat (battery)
Ah
Ampere-hour
AIS
Active intake solenoid
AWG
American wire gauge
B+
Battery voltage
bar
Bar
BAS
Bank angle sensor
BCM
Body control module
BOB
Breakout box
BTDC
Before top dead center
°C
Celsius (Centigrade)
CA
California
CAL
Calibration
CAN
Controller area network
CB Tx
CB send transmission
CB Rx
CB receive transmission
cc
Cubic centimeters
CCA
Cold cranking amps
CCW
Counterclockwise
CKP
Crankshaft position
cm
Centimeters
Cubic centimeters
cm3
CW
Clockwise
DC
Direct current
DLC
Data link connector
DOM
Domestic
DOT
Department of Transportation
DTC
Diagnostic trouble code
DVOM
Digital volt ohm meter
ECM
Electronic control module
ECT
Engine coolant temperature
ECU
Electronic control unit
EEPROM
Electrically erasable programmable read only memory
EFI
Electronic fuel injection
EHCU
Electro hydraulic control unit
ET
Engine temperature
ETC
Electronic throttle control
EVAP
Evaporative emissions control system
°F
Fahrenheit
fl oz
Fluid ounce
FPS
Fuel pressure sensor
ft
Feet
ft-lbs
Foot pounds
FTP
Flash to pass
g
Gram
gal
Gallon
GAWR
Gross axle weight rating
GND
Ground (electrical)
GPS
Global positioning system
GVWR
Gross vehicle weight rating
HCU
Hydraulic control unit
HDI
Harley-Davidson International
HD-Link
Networking system
H-DSSS
Harley-Davidson smart security system
HFM
Hands-free mode
HFSM
Hands-free security module
Hg
Mercury
H02S
Heated oxygen sensor
hp
Horsepower
hr
Hour
IAC
Idle air control
IAT
Intake air temperature
IC
Instrument cluster
ID
Inside diameter
IGN
Ignition light/key switch position
IM
Instrument module
in
inch
Cubic inch
in3
INJ PW
Injector pulse width
INTCM
Intercom
in-lbs
Inch pounds
JSS
Jiffy stand sensor
kg
Kilogram
km
Kilometer
km/h
Kilometers per hour
kPa
Kilopascal
kW
Kilowatt
KS
Knock sensor
L
Liter
lb
Pounds
LCD
Liquid crystal display
LED
Light emitting diode
LH
Left hand
LHCM
Left hand control module
LP
License plate
LT
Left
mA
Milliampere
MAP
Manifold absolute pressure
max
Maximum
mi
Mile
min
Minimum
mL
Milliliter
mm
Millimeter
mph
Miles per hour
ms
Millisecond
Nm
Newton-meter
NIM
Navigation interface module
NiMH
Nickel metal hydride
N/A
Not applicable
O2
Oxygen
OD
Outside diameter
OEM
Original equipment manufacturer
oz
Ounce
P&A
Parts and Accessories
Part No.
Part number
PIN
Personal identification number
PND
Personal navigation device
psi
Pounds per square inch
PWM signal
Pulse width modulated signal
qt
Quart
RAD
Radio
RCM
Reverse control module
RDS
Radio data system
RES
Reserve mark on fuel supply valve
RH
Right hand
RHCM
Right hand control module
rpm
Revolutions per minute
RT
Right
s
Seconds
SCFH
Cubic feet per hour at standard conditions
SDARS
Satellite digital audio radio service
SPDO
Speedometer
SPKR
Speaker
STT
Stop/tail/turn
TA
Traffic announcement
TCA
Throttle control actuator
TDC
Top dead center
TGS
Twist grip sensor
TPMS
Tire pressure monitoring system
TPS
Throttle position sensor
TSM
Turn signal module
TSSM
Turn signal/security module
TT
Telltale
USB
Universal serial bus
V
Volt
VAC
Volts of alternating current
VDC
Volts of direct current
VIN
Vehicle identification number
VR
Voice recognition
VSS
Vehicle speed sensor
W
Watt
WA
Weather alert
WHIM
Wireless headset interface module
WSS
Wheel speed sensor
METRIC CONVERSION
CONVERSION TABLE
Metric Conversions
MILLIMETERS to INCHES
INCHES to MILLIMETERS
(MM x 0.03937 = IN)
(IN x 25.40 = MM)
mm
in
mm
in
mm
in
mm
in
in
mm
in
mm
in
mm
in
mm
.1
.0039
25
.9842
58
2.283
91
3.582
.001
.025
.6
15.240
1-15/16
49.21
3-5/16
84.14
.2
.0078
26
1.024
59
2.323
92
3.622
.002
.051
5/8
15.875
2
50.80
3-3/8
85.72
.3
.0118
27
1.063
60
2.362
93
3.661
.003
.076
11/16
17.462
2-1/16
52.39
3.4
86.36
.4
.0157
28
1.102
61
2.401
94
3.701
.004
.102
.7
17.780
2.1
53.34
3-7/16
87.31
.5
.0197
29
1.142
62
2.441
95
3.740
.005
.127
3/4
19.050
2-1/8
53.97
3-1/2
88.90
.6
.0236
30
1.181
63
2.480
96
3.779
.006
.152
.8
20.320
2-3/16
55.56
3-9/16
90.49
.7
.0275
31
1.220
64
2.519
97
3.819
.007
.178
13/16
20.638
2.2
55.88
3.6
91.44
.8
.0315
32
1.260
65
2.559
98
3.858
.008
.203
7/8
22.225
2-1/4
57.15
3-5/8
92.07
.9
.0354
33
1.299
66
2.598
99
3.897
.009
.229
.9
22.860
2.3
58.42
3-11/16
93.66
1
.0394
34
1.338
67
2.638
100
3.937
.010
.254
15/16
23.812
2-5/16
58.74
3.7
93.98
2
.0787
35
1.378
68
2.677
101
3.976
1/64
.397
1
25.40
2-3/8
60.32
3-3/4
95.25
3
.1181
36
1.417
69
2.716
102
4.016
.020
.508
1-1/16
26.99
2.4
60.96
3.8
96.52
4
.1575
37
1.456
70
2.756
103
4.055
.030
.762
1.1
27.94
2-7/16
61.91
3-13/16
96.84
5
.1968
38
1.496
71
2.795
104
4.094
1/32
.794
1-1/8
28.57
2-1/2
63.50
3-7/8
98.42
6
.2362
39
1.535
72
2.834
105
4.134
.040
1.016
1-3/16
30.16
2-9/16
65.09
3.9
99.06
7
.2756
40
1.575
73
2.874
106
4.173
.050
1.270
1.2
30.48
2.6
66.04
3-15/16
100.01
8
.3149
41
1.614
74
2.913
107
4.212
.060
1.524
1-1/4
31.75
2-5/8
66.67
4
101.6
9
.3543
42
1.653
75
2.953
108
4.252
1/16
1.588
1.3
33.02
2-11/16
68.26
4-1/16
102.19
10
.3937
43
1.693
76
2.992
109
4.291
.070
1.778
1-5/16
33.34
2.7
68.58
4.1
104.14
11
.4331
44
1.732
77
3.031
110
4.331
.080
2.032
1-3/8
34.92
2-3/4
69.85
4-1/8
104.77
12
.4724
45
1.772
78
3.071
111
4.370
.090
2.286
1.4
35.56
2.8
71.12
4-3/16
106.36
13
.5118
46
1.811
79
3.110
112
4.409
.1
2.540
1-7/16
36.51
2-13/16
71.44
4.2
106.68
14
.5512
47
1.850
80
3.149
113
4.449
1/8
3.175
1-1/2
38.10
2-7/8
73.02
4-1/4
107.95
15
.5905
48
1.890
81
3.189
114
4.488
3/16
4.762
1-9/16
39.69
2.9
73.66
4.3
109.22
16
.6299
49
1.929
82
3.228
115
4.527
.2
5.080
1.6
40.64
2-15/16
74.61
4-5/16
109.54
17
.6693
50
1.968
83
3.268
116
4.567
1/4
6.350
1-5/8
41.27
3
76.20
4-3/8
111.12
18
.7086
51
2.008
84
3.307
117
4.606
.3
7.620
1-11/16
42.86
3-1/16
77.79
4.4
111.76
19
.7480
52
2.047
85
3.346
118
4.645
5/16
7.938
1.7
43.18
3.1
78.74
4-7/16
112.71
20
.7874
53
2.086
86
3.386
119
4.685
3/8
9.525
1-3/4
44.45
3-1/8
79.37
4-1/2
114.30
21
.8268
54
2.126
87
3.425
120
4.724
.4
10.160
1.8
45.72
3-3/16
80.96
4-9/16
115.89
22
.8661
55
2.165
88
3.464
121
4.764
7/16
11.112
1-13/16
46.04
3.2
81.28
4.6
116.84
23
.9055
56
2.205
89
3.504
122
4.803
1/2
12.700
1-7/8
47.62
3-1/4
82.55
4-5/8
117.47
24
.9449
57
2.244
90
3.543
123
4.842
9/16
14.288
1.9
48.26
3.3
83.82
4-11/16
119.06
Unless otherwise specified, all fluid volume measurements in this manual are expressed in United States (U.S.) units-of-
measure. See below:
1 pint (U.S.) = 16 fluid ounces (U.S.)
1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.)
1 gallon (U.S.) = 4 quarts (U.S.) = 128 fl. oz. (U.S.)
Fluid volume measurements in this manual include the metric system equivalents. In the metric system, 1 liter (L) = 1,000
milliliters (mL). To convert between U.S. units-of-measure and metric units-of-measure, refer to the following:
fluid ounces (U.S.) x 29.574 = milliliters
pints (U.S.) x 0.473 = liters
quarts (U.S.) x 0.946 = liters
gallons (U.S.) x 3.785 = liters
milliliters x 0.0338 = fluid ounces (U.S.)
liters x 2.114 = pints (U.S.)
liters x 1.057 = quarts (U.S.)
liters x 0.264 = gallons (U.S.)
Fluid volume measurements in this manual do not include the British Imperial (Imp.) system equivalents. The following
conversions exist in the British Imperial system:
1 pint (Imp.) = 20 fluid ounces (Imp.)
1 quart (Imp.) = 2 pints (Imp.)
1 gallon (Imp.) = 4 quarts (Imp.)
Although the same unit-of-measure terminology as the U.S. system is used in the British Imperial (Imp.) system, the actual
volume of each British Imperial unit-of-measure differs from its U.S. counterpart. The U.S. fluid ounce is larger than the
British Imperial fluid ounce. However, the U.S. pint, quart, and gallon are smaller than the British Imperial pint, quart, and
gallon, respectively. To convert between U.S. units and British Imperial units, refer to the following:
fluid ounces (U.S.) x 1.042 = fluid ounces (Imp.)
pints (U.S.) x 0.833 = pints (Imp.)
quarts (U.S.) x 0.833 = quarts (Imp.)
gallons (U.S.) x 0.833 = gallons (Imp.)
fluid ounces (Imp.) x 0.960 = fluid ounces (U.S.)
pints (Imp.) x 1.201 = pints (U.S.)
quarts (Imp.) x 1.201 = quarts (U.S.)
gallons (Imp.) x 1.201 = gallons (U.S.)
The U.S. units of torque, foot pounds and inch pounds, are used in this manual. To convert units, use the following
equations:
foot pounds (ft-lbs) X 12.00000 = inch pounds (in-lbs)
inch pounds (in-lbs) X 0.08333 = foot pounds (ft-lbs)
All metric torque specifications are written in Newton-meters (Nm). To convert metric to United States units and United
States to metric, use the following equations:
Newton meters (Nm) X 0.737563 = foot pounds (ft-lbs)
Newton meters (Nm) X 8.85085 = inch pounds (in-lbs)
foot pounds (ft-lbs) X 1.35582 = Newton meters (Nm)
inch pounds (in-lbs) X 0.112985 = Newton meters (Nm)
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