Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Electrical Diagnostics — page 20
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DELPHI GT 150 SEALED CONNECTORS
A.11
DELPHI GT 150 SEALED CONNECTOR
sm00014a
REPAIR
General
Delphi connectors are embossed with the brand name, Delphi,
on the housing latch or terminal block.
Separating Pin and Socket Housings
See Figure A-23. 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.
1. See Figure A-24. If present, free one side of wire lock (1)
from ear on wire end of socket housing. Release the other
Figure A-23. Delphi GT 150 Sealed Connector: Socket
side if necessary. Release wires from channels in wire
Housing Latch
lock. Remove from socket housing.
2. Use a fingernail to pry colored terminal lock (2) loose.
Remove from mating end of socket housing.
3. Use the thin flat blade from a hobby knife. Gently pry tang
(3) outward away from terminal. Tug on wire to back ter-
minal 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, pre-
venting it from backing 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-16 2013 Softail Diagnostics: Appendix A Connector Repair
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sm00015a
1
2
3
1. Remove wire lock
2. Remove terminal lock
3. Pry tang outward
Figure A-24. Delphi GT 150 Sealed Connector: Removing
Socket Terminals
2013 Softail Diagnostics: Appendix A Connector Repair A-17
HOME
DELPHI GT 280 SEALED 73-TERMINAL ECM
CONNECTOR
A.12
DELPHI GT 280 SEALED 73-TERMINAL ECM
sm06098a
CONNECTOR
NOTE
Do not operate latch lever when connector is not mated to
3
ECU. Damage will occur.
Separating Socket Housing From ECM
See Figure A-25. Remove strap (1). Press the latch (2). Rotate
2
lock lever to the released position (3).
Mating Socket Housing To ECM
1
Push the connector into the ECM. Rotate the lock lever to the
locked position.
1. Strap
Socket Terminal
2. Latch
1. Cut cable strap to release harness from strain relief collar
3. Lock lever released
of connector housing.
Figure A-25. Unlatch ECM Connector
2. See Figure A-26. Release latches (4) that retain cover (3)
to housing (2) and remove cover.
3. Remove and service the Micro-64 terminals. See
sm06093
A.10 DELPHI MICRO 64 SEALED CONNECTORS.
3
4. Install connector housing cover. Verify all wires are within
the confines of the cover and that the cover latches are
engaged.
2
5. Install new cable strap cable to the strain relief of the
connector.
ECM Ground Terminal
4
1. See Figure A-26. Remove secondary lock (1).
1
5
2. See Figure A-27. Using a thin blade screwdriver, gently
pry ground terminal retainer from connector housing.
3. See Figure A-28. Using a thin blade screwdriver, release
latch and pull ground wire, wire seal and terminal from
cover side of housing.
1. Secondary lock
4. Follow instructions in A.9 DELPHI METRI-PACK TER-
2. Terminal housing
MINAL REPAIR to replace the terminal or wire seal.
3. Cover
4. Cover latch
5. Push the terminal into place from the cover side of the
5. Ground secondary lock
connector housing until the latch engages. Pull on wire to
verify terminal is secure.
Figure A-26. Delphi 73-Terminal ECM Connector
NOTE
See Figure A-26. Secondary lock has one short leg and one
long leg. Install as shown.
6. See Figure A-26. Install ground secondary lock (5) and
install secondary lock (1) as shown.
A-18 2013 Softail Diagnostics: Appendix A Connector Repair
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sm06094a
sm06095a
Figure A-27. Remove Ground Secondary Lock
Figure A-28. Remove ECM Ground Terminal
2013 Softail Diagnostics: Appendix A Connector Repair A-19
HOME
DEUTSCH DT SEALED CONNECTORS
A.13
DEUTSCH DT SEALED CONNECTOR
sm00017a
REPAIR
PART NUMBER
TOOL NAME
3
HD-41475
DEUTSCH TERMINAL REPAIR KIT
HD-41475-100
FLAT BLADE L-HOOK
General
1
Deutsch DT sealed connectors are colored coded for location
purposes. DT connectors associated with left side accessories,
such as the front and rear left turn signals, are gray. All other
DT connectors are black.
NOTES
2
•
A DEUTSCH TERMINAL REPAIR KIT (Part No. HD-
41475) contains a selection of seals and seal plugs,
1
locking wedges, attachment clips and terminals.
•
Also included is a FLAT BLADE L-HOOK (Part No. HD-
41475-100) used to remove locking wedges, compart-
1. External latch
mented storage box and carrying case.
2. Socket housing
3. Pin housing
Separating Pin and Socket Housings
Figure A-29. Deutsch DT Sealed Connector
See Figure A-29. To separate the connector halves, Press the
external latch(es) (1) on the socket housing (2) while rocking
the pin (3) and socket housings.
Removing Socket Terminals
NOTES
1. See Figure A-30. Insert a small screwdriver between the
socket housing and locking wedge in-line with the groove
•
Generally, the socket housing is found on the accessory
(in-line with the pin holes if the groove is absent). Turn the
side, while the pin housing is attached to the wiring har-
screwdriver 90 degrees to pop the wedge up and remove
ness.
the secondary locking wedge.
•
Six-place and smaller Deutsch connectors have one latch
2. See Figure A-33. Use a pick or small screwdriver to press
on the connector.
terminal latches inside socket housing and back out
•
Eight- and twelve-place connectors have a latch on each
sockets through holes in rear wire seal.
side. Simultaneously press both latches to separate the
connector.
NOTE
If wire leads require new terminals, see the instructions for
Mating Pin and Socket Housings
crimping terminals.
1. Align the connectors to match the wire lead colors.
Installing Socket Terminals
a. For One External Latch: Six-place and smaller
Deutsch connectors have one external latch on the
1. Match wire lead color to connector cavity.
socket housing. To join the housings, align the latch
2. See Figure A-32. Fit rear wire seal (1) into back of socket
on the socket side with the latch cover on the pin side.
housing (2), if removed.
b. For Two External Latches: Align the tabs on the
3. Grasp wire lead (3) approximately 1.0 in (25.4 mm) behind
socket housing with the grooves on the pin housing.
the socket terminal. Gently push socket through hole in
2. Insert socket housing into pin housing until it snaps or
wire seal into its chambers until it clicks in place.
clicks into place.
4. A tug on the wire will confirm that it is properly locked in
NOTE
place.
For Two External Latches: If latches do not click (latch), press
NOTE
on one side of the connector until that latch engages then press
Install seal plugs (6) into unused chambers. If removed, seal
on the opposite side to engage the other latch.
plugs must be replaced to seal the connector.
3. If necessary, fit the attachment clip to the pin housing.
5. Install internal seal (4) on lip of socket housing, if removed.
4. Place large end of slot on attachment clip over T-stud on
6. Insert tapered end of secondary locking wedge (5) into
frame. Push assembly forward to engage small end of
socket housing and press down until it snaps in place. The
slot.
A-20 2013 Softail Diagnostics: Appendix A Connector Repair
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wedge fits into the center groove within the socket housing
sm00018
and holds the terminal latches tightly closed.
NOTES
•
See Figure A-31. While rectangular wedges do not require
2
a special orientation, align arrow (1) on conical secondary
locking wedge towards external latch for three-place con-
nectors.
•
If the secondary locking wedge does not slide into position
easily, check the installation of all the terminals. Unseated
terminals prevent the locking wedge from proper installa-
tion.
1
sm00009a
1. Arrow on socket locking wedge
2. Arrow on pin locking wedge
Figure A-31. Deutsch DT Sealed Connector: 3-Place
Locking Wedges
Figure A-30. Deutsch DT Sealed Connector: Remove
Secondary Locking Wedge
2013 Softail Diagnostics: Appendix A Connector Repair A-21
HOME
NOTES
sm00010
•
If wire leads require new terminals, see the instructions
for crimping terminals.
•
The 8-place and 12-place gray and black connectors are
not interchangeable. If replacing both the socket and pin
housings, the black may be substituted for the gray.
•
The socket and pin housings of all other connectors are
interchangeable. Black may be mated with the gray since
the alignment tabs are absent and the orientation of the
external latch is the same.
sm00019
5
6
4
2
1
Figure A-33. Deutsch DT Sealed Connector: Press Terminal
Latch and Back Out Pin
3
1. Wire seal
Installing Pin Terminals
2. Socket housing
1.
See Figure A-34. Fit wire seal (1) into back of pin housing
3. Wire lead
(2).
4. Internal seal
5. Secondary locking wedge
2.
Grasp wire lead approximately 1.0 in (25.4 mm) behind
6. Seal plug
the pin terminal (3). Gently push pin through holes in wire
seal into its respective numbered chamber until it "clicks"
Figure A-32. Deutsch DT Sealed Connector: 2, 3, 4 and
in place.
12-Place Socket Housings
NOTE
A tug on the wire lead will confirm that a pin is locked in place.
Removing Pin Terminals
3.
Insert tapered end of secondary locking wedge (4) into
1. Use the hooked end of a stiff piece of mechanics wire, a
pin housing. Press down until it snaps in place.
needle nose pliers or the FLAT BLADE L-HOOK (Part
No. HD-41475-100) to remove the secondary locking
NOTES
wedge.
•
The wedge fits in the center groove of the pin housing and
2. Gently press terminal latches inside pin housing and back
holds the terminal latches tightly closed.
out pins through holes in wire seal.
•
See Figure A-31. While rectangular wedges do not require
a special orientation, align arrow (1) on conical secondary
locking wedge towards external latch for three-place con-
nectors.
•
If the secondary locking wedge does not slide into position
easily, check the installation of all the terminals. Unseated
terminals prevent the locking wedge from proper installa-
tion.
A-22 2013 Softail Diagnostics: Appendix A Connector Repair
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Crimping Terminals
sm00020
3
Identify which of the types of Deutsch terminals are used with
the connector. Follow the corresponding crimping instructions.
1
Refer to Table A-2.
2
4
1. Wire seal
2. Pin housing
3. Pin terminal
4. Locking wedge
Figure A-34. Deutsch DT Sealed Connector: 2, 3, 4 and
12-Place Pin Housings
Table A-2. Deutsch Connector: Terminal Crimping Instructions
TYPE
CRIMPING INSTRUCTIONS
DT Sealed (with crimp tails)
A.14 DEUTSCH DT SEALED TERMINAL REPAIR
DTM Mini Sealed
Terminal (solid
A.16 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR
barrel)
DTM
Mini Sealed Terminal (with crimp
A.15 DEUTSCH DTM SEALED MINI TERMINAL REPAIR
tails)
2013 Softail Diagnostics: Appendix A Connector Repair A-23
HOME
DEUTSCH DT SEALED
TERMINAL REPAIR
A.14
NOTE
DEUTSCH DT SEALED TERMINAL CRIMPS
If the crimp tails are slightly out of alignment, the crimp tool
rotates the terminal to face the tails upward. When positioned,
PART NUMBER
TOOL NAME
the locking bar fits snugly in the space between the contact
HD-39965-A
DEUTSCH TERMINAL CRIMP TOOL
band and the core crimp tails.
5. Insert stripped wire core between crimp tails until ends
Preparing Wire Leads for Crimping
make contact with locking bar. Position wire that the wide
1. Use a shop gauge to determine gauge of wire lead.
pair of crimp tails squeeze bare wire strands, while the
narrow pair folds over the insulation material.
2. Strip 5/32 in (4.0 mm) of insulation from the wire lead.
6. Squeeze handle of crimp tool until tightly closed. Tool
Crimping Terminal to Lead
automatically opens after the terminal is crimped.
1. See Figure A-35. Squeeze the handles of the DEUTSCH
7. Raise locking bar up to remove wire lead and terminal.
TERMINAL CRIMP TOOL (Part No. HD-39965-A) to open
the jaws. Push the locking bar (1) up.
Inspecting Crimps
2. Match the wire gauge to the crimp tool die. Refer to
Inspect the wire core and insulation crimps. Distortion should
Table A-3.
be minimal.
NOTE
Table A-3. Deutsch DT Sealed Terminal Crimp:Wire Gauge
Rest the rounded side of the contact barrel in the nest (concave
To Die
split level area) with the crimp tails facing up.
WIRE GAUGE (AWG)
CRIMP TOOL DIE
3. Insert (2) terminal (socket/pin) through hole of the locking
bar.
20
Front
4. Release locking bar to lock terminal in die.
16-18
Middle
sm00021
5
2
1
6
4
3
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 to remove terminal
Figure A-35. Crimping a Deutsch DT Sealed Terminal
A-24 2013 Softail Diagnostics: Appendix A Connector Repair
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DEUTSCH DTM SEALED MINI TERMINAL
REPAIR
A.15
DEUTSCH DTM SEALED MINI TERMINAL
Inspecting Crimps
CRIMPS
Inspect the core and insulation crimps. Distortion should be
minimal.
PART NUMBER
TOOL NAME
sm00022
HD-38125-7
PACKARD TERMINAL CRIMPER
Preparing Wire Leads for Crimping
1
Strip 5/32 in (4.0 mm) of insulation from the wire lead.
Crimping a Mini Terminal to Wire Lead
1. See Figure A-36. 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. Verify
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-
2
ition wire that the 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, squeeze the ratchet trigger (2).
6. Position the insulation crimp on nest C of the crimper.
Verify the insulation crimp tails are facing the forming jaws.
7. Squeeze handle of crimp tool until tightly closed. Tool
1.
E die
automatically opens when the crimping sequence is com-
2.
Crimper ratchet trigger
plete.
Figure A-36. Packard Terminal Crimper (HD-38125-7)
2013 Softail Diagnostics: Appendix A Connector Repair A-25
HOME
DEUTSCH DTM SEALED SOLID BARREL MINI
TERMINAL REPAIR
A.16
DEUTSCH DTM SEALED SOLID BARREL
sm00023
TERMINAL CRIMPS
5
PART NUMBER
TOOL NAME
4
HD-42879
ELECTRICAL CRIMPER TOOL
Preparing Wire Leads For Crimping
For size 20, 16 and 12 contacts, wire ranges 26-12 AWG.
Strip 1/4 in (6.4 mm) of insulation from the wire lead.
1
Adjusting Crimper Tool
3
1. See Figure A-37. 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).
2
3. Raise selector knob. Roate knob 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-38. 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 recess in indentor cover. Tighten
knurled locknut.
3. Slowly squeeze handles of crimp tool until contact centers
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
1.
Locking pin
closed. Tool automatically opens when the crimping
2.
Selector knob
sequence is complete.
3.
SEL. NO. arrow
4.
Knurled locknut
5. Remove wire lead with crimped contact from indentor.
5.
Adjusting screw
NOTE
Figure A-37. Electrical Crimper Tool (HD-42879)
Adjust the crimper tool for each contact/wire size.
6. Install pin to lock selector knob.
Inspecting Crimps
Inspect the crimp. All core wire strands are to be crimped in
the barrel.
A-26 2013 Softail Diagnostics: Appendix A Connector Repair
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sm00024
2
1
3
3
4
1. Contact barrel
2. Indentor cover
3. Indentor point
4. Stripped wire lead
Figure A-38. Deutsch Solid Barrel
2013 Softail Diagnostics: Appendix A Connector Repair A-27
HOME
JAE MX19 SEALED CONNECTORS
A.17
JAE MX19 SEALED CONNECTORS
sm06926
2
PART NUMBER
TOOL NAME
B-50085
TERMINAL EXTRACTOR
Connector Housings
Separate Housings: See Figure A-39. Press the two release
buttons on each side of the housing to separate the connector.
1
2
1
Connect Housings: Align housings. Press together until the
locking tabs click.
sm06925
1. Extractor
2. Plastic molding
Figure A-40. JAE MX19 Terminal Removal
CRIMPING TERMINALS
PART NUMBER
TOOL NAME
HD-50120
UNIVERSAL CRIMPER SET
HD-50120-2
HAND CRIMP FRAME
HD-50120-6
JAE DIE
Figure A-39. Release Buttons: JAE MX19 Sealed Connector
1. Strip the wire insulation to specification. Refer to Table A-4.
Removing Terminals
2. Install the JAE DIE (Part No. HD-50120-6) in the handle
1. Modify a TERMINAL EXTRACTOR (Part No. B-50085)
of the HAND CRIMP FRAME (Part No. HD-50120-2) of
by filing the front edge to 45 degrees.
the UNIVERSAL CRIMPER SET (Part No. HD-50120).
2. See Figure A-40. Insert the extractor (1) into the opening
3. Place the new terminal in the specified nest.
above the terminal and press the plastic molding (2) up
4. Insert the wire to the wire stop. Crimp the terminal.
and out of the way.
5. Inspect the crimped terminal.
3. Pull the wire lead and terminal out of the back of the
housing.
Table A-4. JAE MX19 Crimper Die (Part No. HD-50120-6)
Installing Terminals
TERMINAL
PART NO.
STRIP LENGTH
NEST
1. Inspect the plastic molding and replace the connector
in
mm
housing if necessary.
Socket
72910-11
0.051-0.098
2.0-2.5
B
2. Orient the terminal to the housing. Push terminal into
housing until it clicks into place.
Pin
72909-11
0.051-0.098
2.0-2.5
A
A-28 2013 Softail Diagnostics: Appendix A Connector Repair
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MOLEX CMC SEALED CONNECTORS
A.18
MOLEX CMC SEALED CONNECTORS
Installing Terminals
1. Orient the terminal to the housing cavity. Snap the terminal
PART NUMBER
TOOL NAME
in place.
HD-50423
0.6 MM TERMINAL EXTRACTOR
2. Slide the cap over the lead bundle. Snap the cap in place.
TOOL
3. Install a cable strap through the guide and around the lead
HD-50424
1.5 MM TERMINAL EXTRACTOR
bundle.
TOOL
sm06936
Separating the Connector
Release: See Figure A-41. Press the catch and rotate the lever
arm down.
Connect: Press on the front guard to release the latch and
2
rotate the lever arm up until the catch clicks in place.
sm06931
1
3
Figure A-41. Release
1. Press latch
2. Press cap and latch
3. Remove cap
Removing Terminals
Figure A-42. Remove the Wire Lead Cap
1. With the lever arm open, cut the cable strap around the
wire bundle.
2. See Figure A-42. Open a wire cap latch (1) with a small
sm06928
screwdriver.
3. Maintain pressure on the cap and open the opposite latch
(2) with the screwdriver.
4. Slide the cap off (3).
5. See Figure A-43. Use the screwdriver to open the sec-
ondary lock. Pull the locking bar all the way out.
6. See Figure A-44. Locate the wire lead cavity by the alpha-
numeric coordinates.
7. Identify the size of the terminal and select either the CMC
extractor 0.6 MM TERMINAL EXTRACTOR TOOL (Part
No. HD-50423) or the 1.5 MM TERMINAL EXTRACTOR
TOOL (Part No. HD-50424).
Figure A-43. Molex CMC Sealed Connector Secondary
8. See Figure A-45. Insert the pins of the CMC extractor tool
Lock
(1) into the access slots (2) of the terminal cavity and
retract the lead and terminal.
2013 Softail Diagnostics: Appendix A Connector Repair A-29
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CRIMPING TERMINALS
sm06927
PART NUMBER
TOOL NAME
1
2
HD-50120
UNIVERSAL CRIMPER SET
2
HD-50120-2
HAND CRIMP FRAME
HD-50120-3
JAE DIE
2
HD-50120-4
JAE DIE
1. Select the crimper die according to the terminal part
1
number from the UNIVERSAL CRIMPER SET (Part
2
No. HD-50120).
2. Strip the wire insulation to specification. Refer to Table A-5
1. Alpha
or Table A-6.
2. Numeric
3. Install the JAE DIE (Part No. HD-50120-3) or JAE DIE
Figure A-44. Alpha-Numeric Coordinates
(Part No. HD-50120-4) in the handle of the HAND CRIMP
FRAME (Part No. HD-50120-2).
4. Place the new terminal in the specified nest.
sm06935
5. Insert the wire to the wire stop. Crimp the terminal.
6. Inspect the crimped terminal.
1
Table A-5. Molex CMC Sealed Crimper Die (Part No.
HD-50120-3)
PART
TERMINAL:
STRIP LENGTH
NEST
NO.
WIRE GAUGE
in
mm
72226-11
Socket:
16 AWG
0.177
4.5
B
72227-11
Socket:
18 AWG
0.177
4.5
A
Table A-6. Molex CMC Sealed Crimper Die (Part No.
HD-50120-4)
PART NO.
TERMINAL:
STRIP LENGTH
NEST
2
WIRE GAUGE
in
mm
72222-11
Socket:
18 AWG
0.138
3.5
B
72222-11
Socket:
20 AWG
0.138
3.5
A
1. Extractor tool
2. Access slots
Figure A-45. Terminal Removal
A-30 2013 Softail Diagnostics: Appendix A Connector Repair
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MOLEX MX 150 SEALED CONNECTORS
A.19
5. With all terminals installed, push the secondary lock into
MOLEX MX 150 SEALED CONNECTOR
the socket housing to lock the wire terminals into the
REPAIR
housing.
PART NUMBER
TOOL NAME
sm00040a
HD-48114
TERMINAL REMOVER
Separating Pin and Socket Housings
See Figure A-46. 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 Figure A-47. Use a small
screwdriver in the pry slot. The slot next to the
Figure A-46. Molex MX 150 Sealed Connector: Latch
external latch provides a pivot point.
b. Pin Housing: See Figure A-48. Use needle nose
sm03332a
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 Figure A-49. 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.
Figure A-47. Secondary Lock Pry Slot (Socket Housing)
Installing Terminals
1. See Figure A-50. 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. Determine the cavity number by counting
the cavities up or down along the row from each stamped
number.
2. Orient the terminal 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.
2013 Softail Diagnostics: Appendix A Connector Repair A-31
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CRIMP TERMINAL TO LEAD
sm02851a
PART NUMBER
TOOL NAME
HD-48119
TERMINAL CRIMPER
Prepare Lead
1. Cut the damaged terminal close to the back of the terminal
to leave as much wire length as possible.
2. Strip wire lead removing 3/16 in (4.70-5.60 mm) of insula-
tion.
NOTE
The strip length is the same for both pin and socket terminals
and for wire gauges from 22 to 14.
Figure A-48. Pull Up Secondary Lock
Prepare Tool
1. Identify the punch/die in the jaws of the TERMINAL
sm00043a
CRIMPER (Part No. HD-48119) for the wire gauge. Refer
to Table A-7.
2. Squeeze and release the handles to open the tool.
NOTE
The crimp tool automatically opens when the handles are
released.
3. See Figure A-51. 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.
Figure A-49. Molex MX 150 Sealed Connector: Terminal
Table A-7. Crimp Tool Wire Gauge Punch/Die
Remover (HD-48114)
AWG (WIRE GAUGE)
PUNCH/DIE
22
Left
sm00044
18-20
Middle
3
14-16*
Right
1
* Crimp 16 AWG pin terminals in the 18-20 middle die.
2
1. Cavity number
2. Tang
3. Cavity slot
Figure A-50. Molex MX 150 Sealed Connector: Pin Cavities
and Wire Terminal
A-32 2013 Softail Diagnostics: Appendix A Connector Repair
HOME
2. See Figure A-55. Ratchet the handles together until the
sm02853a
crimp tails are held in vertical alignment between the punch
and the die.
sm02855a
Figure A-51. Open Terminal Crimper (HD-48119) at 45
Degrees
Figure A-53. Square Openings in Socket Locator Bar
sm02854a
Insert Stripped Lead
See Figure A-56. 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.
1
NOTES
2
•
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.
sm02856a
1. Socket locator bar
2. Pin locator bar
Figure A-52. Terminal Locator Bars
Position Terminal in the Punch/Die
1. See Figure A-53. With the crimp tails up, place the terminal
through the punch/die into the square opening in the
Figure A-54. Pin Terminal against Pin Locator Bar
socket locator bar.
a. Socket Terminal: See Figure A-52. A socket terminal
stops against the back face of the socket locator bar
(1).
b. Pin Terminal: See Figure A-54. 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.
2013 Softail Diagnostics: Appendix A Connector Repair A-33
HOME
Inspect Crimp
sm02857a
1. Inspect Crimp: Inspect the core and insulation crimp.
a. See Figure A-57. 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. Pull the lead.
sm02859
3
1
2
Figure A-55. 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
1. Core crimp
Open a stuck or jammed tool by pressing the ratchet release
2. Wire strands
lever found between the handles. Do not force the handles
3. Insulation crimp
open or closed.
Figure A-57. Terminal Crimp
sm02858a
Figure A-56. Stripped Lead at Up Angle
A-34 2013 Softail Diagnostics: Appendix A Connector Repair
HOME
TYCO
070 MULTILOCK UNSEALED CONNECTOR
A.20
TYCO 070 MULTILOCK UNSEALED
sm00002a
CONNECTOR REPAIR
2
3
PART NUMBER
TOOL NAME
4
HD-41609
AMP MULTI-LOCK CRIMPER
SNAP-ON
TT600-3
SNAP-ON PICK
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 Figure A-58. 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.
1
NOTE
For terminal crimping use the AMP MULTI-LOCK CRIMPER
1. Attachment clip
(Part No. HD-41609).
2. Release button
3. Socket housing
Separating Pin and Socket Housings
4. Pin housing
1. If necessary, slide connector attachment clip T-stud to the
Figure A-58. Tyco 070 Multilock Unsealed Connector
large end of the opening.
2. See Figure A-58. Press the release button (2) on the
Removing Terminals from Housing
socket terminal side of the connector and pull the socket
housing (3) out of the pin housing (4).
1. See Figure A-59. Bend back the latch (1) to free one end
of secondary lock (2) then repeat on the opposite end.
Mating Pin and Socket Housings
Hinge the secondary lock outward.
1. Hold the housings to match wire color to wire color.
2. Look in the terminal side of the connector (opposite the
2. Insert the socket housing into the pin housing until it clicks
secondary lock) and note the cavity next to each terminal.
in place.
3. Insert a pick or pin into the terminal cavity until it stops.
3. If OE location is a T-stud, fit large opening end of attach-
NOTE
ment clip over T-stud and slide connector to engage T-
If socket/pin terminal tool is not available, use a push pin/safety
stud to small end of opening.
pin or a SNAP-ON PICK (Part No. SNAP-ON TT600-3).
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.
2013 Softail Diagnostics: Appendix A Connector Repair A-35
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