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Harley Davidson 2009 Dyna Models. Service manual - page 24

Table 7-13. Handlebar Switch Assembly Fasteners

TORQUE

FASTENER

60-80 in-lbs (6.8-9.0 Nm)

Handlebar switch clamp
screws

35-45 in-lbs (4.0-5.1 Nm)

Switch housing screws

12. Remove the cardboard insert between the brake lever and

lever bracket.

13. Adjust throttle cables. See

2.22 THROTTLE CONTROL

14. Install main fuse. See

7.7 FUSES AND RELAYS

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

15. Test the switches for proper operation.

16. Secure wire harness to handlebar as necessary.

sm01086

Switch housing assembly

Tab

Groove

Brake lever bracket

Figure 7-89. Switch Housing Alignment (typical)

sm02633

Upper screw

Lower screw and flat washer

Figure 7-90. Handlebar Switch Clamp Screws

DISASSEMBLY

Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)

Place the cardboard insert between the brake lever and
lever bracket.

Using a T25 TORX drive head, remove the upper and
lower switch housing screws.

If replacing lower housing switches, perform steps 4
through 7 before continuing to repair section. If replacing
upper housing switches, proceed directly to repair section.

See

Figure 7-90

. Using a T27 TORX drive head, loosen

the upper screw (1) securing the handlebar switch clamp
to the master cylinder housing. Remove the lower clamp
screw with flat washer (2).

Remove the brass ferrules from the notches on the inboard
side of the throttle control grip. Remove the ferrules from
the cable end fittings.

Remove the friction shoe from the end of the tension
adjuster screw.

NOTE

The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.

Remove the throttle control grip from the end of the
handlebar.

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7-68 2009 Dyna Service: Electrical

SWITCH REPAIR/REPLACEMENT

Upper Housing Repair

NOTE

Replace the engine stop and engine start switches as a single
assembly even if only one switch is determined to be faulty.

See

Figure 7-91

. From inside the switch housing, remove

the screw with lockwasher (4) to release the bracket (5).
Remove the bracket and switch assembly from the
housing.

Move cable conduit (3) from beneath wing of bracket. Cut
wires 0.25 in. (6.4 mm) from old switches (1, 2). Discard
old switch and bracket assembly.

Slide conduit forward over cut ends of switch wires and
cut off 0.5 in. (12.7 mm) of conduit (3) material. Push
conduit back to access switch wires.

See

Figure 7-92

. Separate new engine stop switch (2)

and engine start switch (1) wires into two bundles.

NOTE

Replacement stop switch and start switch wires are cut to
length, 2.5 in. (63.5 mm) and 2.0 in. (50.8 mm) respectively,
and partially stripped.

See

7.32 HANDLEBAR SWITCH ASSEMBLIES

for

information on splicing and general repair practices.

Loop switch wires so that spliced lengths are positioned
as shown in

Figure 7-92

. Route wires downstream of

splices beneath wing on engine stop switch side of bracket
as shown in

Figure 7-91

See

Figure 7-92

. Install a new7.0 in. (177.8 mm) cable

strap (5) beneath wing on engine start switch side (1) of
bracket and capture wire splices (4).

Place switch assembly into upper housing aligning hole
in bracket with threaded hole in boss. Be sure that bracket
is fully seated. The step at the edge of the boss captures
the bottom edge of the bracket, while tabs on each side
of the bracket fit in slots cast into the housing.

See

Figure 7-91

. Install screw and lockwasher (4) to

secure bracket (5) inside housing. Verify that wing on
engine stop switch (2) side of bracket captures edge of
conduit (3) as shown.

10. Securely tighten cable strap to draw splices to bracket.

Remove any excess cable strap material.

11. Continue with

7.33 RIGHT HANDLEBAR SWITCH,

Assembly

sm01087

Start switch

Stop switch

Conduit

Screw with lockwasher

Bracket

Figure 7-91. Upper Housing Without Splices

sm01088

Start switch

Stop switch

Conduit

Splices

Cable strap

Figure 7-92. Upper Housing With Splices

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2009 Dyna Service: Electrical 7-69

Lower Housing Repair

From inside the switch housing, carefully cut cable strap
to free conduit from the turn signal switch bracket.

Remove the screw with lockwasher to release the turn
signal switch bracket. Remove the bracket and switch
assembly from the housing.

Continue with TURN-RIGHT SIGNAL SWITCH or FRONT
STOPLIGHT SWITCH procedures which follow.

Turn-Right Signal Switch

Perform steps in LOWER HOUSING REPAIR.

Cut wire 1.5 in. (38.1 mm) from old switch. Discard old
switch assembly.

NOTE

Replacement turn-right signal switch wires are cut to length of
1.5 in. (38.1 mm) and partially stripped.

See

7.32 HANDLEBAR SWITCH ASSEMBLIES

for

information on splicing and general repair practices.

Continue with

7.33 RIGHT HANDLEBAR SWITCH,

Assembly

Front Stoplight Switch

Perform steps in LOWER HOUSING REPAIR.

Carefully remove the wedge between the switch and switch
housing, if present. To remove the switch from the housing,
depress the plunger and slowly rotate switch upward while
rocking slightly.

Cut wires 1.0 in. (25.4 mm) from old switch. Discard old
switch.

NOTE

Replacement stoplight switch wires are cut to length of 2.5 in.
(63.5 mm) and partially stripped.

See

7.32 HANDLEBAR SWITCH ASSEMBLIES

for

information on splicing and general repair practices.

Carefully depress plunger against inside wall of switch
housing. With thumb over plunger bore, move switch into
the installed position in the switch housing cavity. When
plunger is positioned against thumb, slowly rotate switch
downward while rocking slightly. Release the plunger only
after switch is properly positioned in the cavity.

Verify that the plunger is square in the bore and that the
boot is not compressed, collapsed or torn. If necessary,
gently work the plunger in and out until boot is fully
extended.

See

Figure 7-93

. Push down on switch (1) so that it bot-

toms against housing and wires (3) run in groove at base
of cavity. With the concave side facing outward, insert
wedge (2) between switch and outboard side of switch
housing.

Push wedge down until it also bottoms against housing.
Verify that the plunger is still square in the bore and then
place a drop of RTV Silicone Sealant on upper corner of
wedge.

Continue with

7.33 RIGHT HANDLEBAR SWITCH,

Assembly

sm01089

Stoplight switch

Wedge

Switch wires

Lower switch housing

Figure 7-93. Install Stoplight Switch

ASSEMBLY

See

Figure 7-94

. Insert tapered end of new7.0 in. (177.8

mm) cable strap (1) into round hole in turn signal switch
bracket (2) and then feed back through using the adjacent
hole. Reserve the oblong hole for the bracket screw.

NOTE

Be sure that all splices are positioned above the turn signal
switch bracket.

Place the turn signal switch assembly into the housing,
aligning the oblong hole in the bracket with the threaded
hole in the boss. Be sure that the bracket is fully seated.
Tabs on each side of bracket are captured in slots cast
into switch housing.

Start screw with lockwasher to secure bracket inside
housing.

If routed incorrectly, wires can be pinched by casting or
handlebar resulting in switch failure. (00542b)

Loop switch wires so that spliced lengths are positioned
across bracket.

Capturing conduit about 0.25 in. (6.4 mm) from end,
securely tighten cable strap to draw conduit to bracket.
Remove any excess cable strap material.

Install second 7.0 in. (177.8 mm) cable strap capturing
conduit and wire splices. Securely tighten cable strap to

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7-70 2009 Dyna Service: Electrical

draw splices to conduit. Remove any excess cable strap
material.

Tighten screw to secure bracket inside housing.

Route wire bundle to upper switch housing by gently
pressing conduit into channel next to angular arm of
bracket. Secure bundle to arm using third cable strap. Cut
any excess cable strap material. If necessary, bend
angular arm of bracket downward to firmly secure front
stoplight switch in position.

See

7.33 RIGHT HANDLEBAR SWITCH, Installation

If lower housing switches were replaced, perform the
entire procedure.

If upper housing switches were replaced, begin with
step 11.

sm01090

Cable strap

Bracket

Right turn signal switch

Figure 7-94. Insert Cable Strap in Switch Bracket

HOME

2009 Dyna Service: Electrical 7-71

7.34

LEFT HANDLEBAR SWITCH

REMOVAL

NOTE

The removal and installation steps listed apply when replacing
the entire switch assembly, switch housing or handlebars.

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Remove main fuse. See

7.7 FUSES AND RELAYS

Using a T25 TORX drive head, loosen but do not remove
the upper and lower switch housing screws.

Using a T27 TORX drive head, remove the two screws
with flat washers securing the handlebar clamp to the
clutch lever bracket. Remove the clutch hand lever
assembly and clamp from the handlebar.

Remove the upper and lower switch housing screws.

Remove the grip sleeve from the end of the handlebar if
damaged.

INSTALLATION

If the grip sleeve was removed, thoroughly clean handlebar
to remove all adhesive residue. Pour adhesive into new
grip. Roll grip to evenly distribute adhesive on inside sur-
faces. Install grip on handlebar with a twisting motion.

See

Figure 7-95

. Install upper and lower switch housings

on handlebar. Be sure that ribs (2) on outboard side of
switch housings fit in grooves (3) molded into grip.

Verify that the wire harness conduit runs in the groove at
the bottom of the handlebar. Be sure that the upper switch
housing harness will not be pinched under the handlebar
when the switch housing screws are tightened.

Start the upper and lower switch housing screws, but do
not tighten.

See

Figure 7-96

. Position the clutch hand lever assembly

inboard of the switch housing assembly, engaging the tab
(3) on the lower switch housing in the groove (2) at the
bottom of the clutch lever bracket.

Align the holes in the handlebar switch clamp with those
in the clutch lever bracket and start the two screws (with
flat washers). Position for rider comfort. Beginning with
the top screw, tighten screws to specification with a T27
TORX drive head. Refer to

Table 7-14

Using a T25 TORX drive head, tighten lower and upper
switch housing screws to specification. Refer to

Table 7-14

NOTE

Always tighten the lower switch housing screw first so that any
gap between the upper and lower housings is at the front of
the switch.

Table 7-14. Handlebar Switch Assembly Fasteners

TORQUE

FASTENER

60-80 in-lbs (6.8-9.0 Nm)

Handlebar switch clamp
screws

35-45 in-lbs (4.0-5.1 Nm)

Switch housing screws

Install main fuse. See

7.7 FUSES AND RELAYS

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

Test the switches for proper operation.

10. Secure wire harness to handlebar as necessary.

sm02632

Grip sleeve

Ribs

Grooves

Figure 7-95. Left Handlebar Switch Housings

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7-72 2009 Dyna Service: Electrical

sm02631

Clutch lever bracket

Groove

Tab

Switch housing assembly

Figure 7-96. Clutch Lever Bracket

DISASSEMBLY

Using a T25 TORX drive head, remove the upper and
lower switch housing screws.

If replacing lower housing switches, perform next step
before continuing to repair section. If replacing upper
housing switches, proceed directly to repair section.

Using a T27 TORX drive head, loosen the upper screw
securing the handlebar clamp to the clutch lever bracket.
Remove the lower clamp screw with flat washer.

SWITCH REPAIR/REPLACEMENT

Upper Housing Repair

NOTE

Replace the horn switch and high/low beam switch as a single
assembly even if only one switch is determined to be faulty.

See

Figure 7-97

. From inside the switch housing, remove

the screw with lockwasher (4) to release the bracket (5).
Remove bracket and switch assembly from the housing.

Move cable conduit (3) from beneath wing of bracket. Cut
wires 0.25 in. (6.4 mm) from old switches (1, 2). Discard
old switch and bracket assembly.

Slide conduit forward over cut ends of switch wires and
cut off 0.5 in. (12.7 mm) of conduit (3) material. Push
conduit back to access switch wires.

Separate the new horn switch (1) and high/low beam
switch (2) wires into two bundles.

NOTE

Replacement high/low beam switch and horn switch wires are
cut to length of 2.5 in. (63.5 mm) and 2.0 in. (50.8 mm)
respectively, and partially stripped.

See

7.32 HANDLEBAR SWITCH ASSEMBLIES

for

information on splicing and general repair practices.

Loop switch wires so that spliced lengths are positioned
as shown in

Figure 7-98

. Route wires downstream of

splices beneath wing on high/low beam switch side of
bracket as shown in

Figure 7-97

See

Figure 7-98

. Install a new7.0 in. (177.8 mm) cable

strap (5) beneath wing on horn switch side (1) of bracket
and capture wire splices (4).

See

Figure 7-97

. Install screw and lockwasher (4) to

secure bracket (5) inside housing. Verify that wing on
high/low switch (2) side of bracket captures edge of conduit
(3) as shown.

10. Securely tighten cable strap to draw splices to bracket.

Remove any excess cable strap material.

11. Continue with

7.34 LEFT HANDLEBAR SWITCH,

Assembly

sm01091

Horn switch

High/low beam switch

Conduit

Screw with lockwasher

Bracket

Figure 7-97. Upper Housing Without Splices

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2009 Dyna Service: Electrical 7-73

sm01092

Horn switch

High/low beam switch

Conduit

Splices

Cable strap

Figure 7-98. Upper Housing With Splices

Lower Housing Repair

From inside the switch housing, carefully cut cable strap
to free conduit from the turn signal switch bracket.

Remove screw with lockwasher to release the turn signal
switch bracket. Remove the bracket and switch assembly
from the housing.

Continue with TURN-LEFT SIGNAL SWITCH or CLUTCH
INTERLOCK SWITCH procedures.

Turn-Left Signal Switch

Perform steps in LOWER HOUSING REPAIR.

Cut wires 1.5 in. (38.1 mm) from old switch (Turn-L(eft)
Signal Switch). Discard switch assembly.

NOTE

Replacement turn-right signal switch wires are cut to length of
1.5 in. (38.1 mm) and partially stripped.

See

7.32 HANDLEBAR SWITCH ASSEMBLIES

for

information on splicing and general repair practices.

Continue with

7.34 LEFT HANDLEBAR SWITCH,

Assembly

Clutch Interlock Switch

Perform steps in LOWER HOUSING REPAIR.

See

Figure 7-99

. Cut wires 0.25 in. (6.4 mm) from old

switch. Discard switch assembly.

NOTE

Replacement turn-right signal switch wires are cut to length
and partially stripped.

See

7.32 HANDLEBAR SWITCH ASSEMBLIES

for

information on splicing and general repair practices.

Continue with

7.34 LEFT HANDLEBAR SWITCH,

Assembly

sm02644

Figure 7-99. Clutch Interlock Switch

ASSEMBLY

See

Figure 7-100

. Insert tapered end of new 7.0 in. (177.8

mm) cable strap (1) into round hole in turn signal switch
bracket (2) and then feed back through using the adjacent
hole. Reserve the oblong hole for the bracket screw.

NOTE

Be sure that all splices are positioned above the turn signal
switch bracket.

Place the turn signal switch assembly (3) into the housing,
aligning the oblong hole in the bracket with the threaded
hole in the boss. Be sure that the bracket is fully seated.
Tabs on each side of bracket are captured in slots cast
into switch housing.

Start screw with lockwasher to secure bracket inside
housing.

If routed incorrectly, wires can be pinched by casting or
handlebar resulting in switch failure. (00542b)

Loop switch wires so that spliced lengths are positioned
across bracket.

Capturing conduit about 0.25 in. (6.4 mm) from end,
securely tighten cable strap to draw conduit to bracket.
Remove any excess cable strap material.

Tighten screw to secure bracket inside housing.

Route wire bundle to upper switch housing below and then
forward of the main wire harness, positioning conduit in
channel next to angular arm of bracket. Secure bundle to

HOME

7-74 2009 Dyna Service: Electrical

arm using new cable strap. Cut any excess cable strap
material.

See

7.34 LEFT HANDLEBAR SWITCH, Installation

If lower housing switches were replaced, perform the
whole procedure.

If upper housing switches were replaced, begin with
step 7.

Verify the operation of the clutch interlock switch. See the
ELECTRICAL DIAGNOSTIC MANUAL.

sm01094

Cable strap

Bracket

Left turn signal switch

Figure 7-100. Insert Cable Strap in Switch Bracket

HOME

2009 Dyna Service: Electrical 7-75

TABLE OF CONTENTS

SUBJECT

............................................................................................................................

PAGE NO.

APPENDIX A CONNECT

OR REP

AIR

A.1

AMP MULTILOCK CONNECTORS

AMP MULTILOCK CONNECTOR REPAIR

TOOL NAME

PART NUMBER

AMP MULTILOCK CRIMPER

HD-41609

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-1

. 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

If necessary, slide connector attachment clip T-stud to the
large end of the opening.

See

Figure A-1

. Depress the release button (2) on the

socket terminal side of the connector and pull the socket
housing (3) out of the pin housing (4).

Mating Pin and Socket Housings

Hold the housings to match wire color to wire color.

Insert the socket housing into the pin housing until it snaps
in place.

If OE location is a T-stud, fit large opening end of attach-
ment clip over T-stud and slide connector to engage T-
stud to small end of opening.

sm00002

Attachment clip

Release button

Socket housing

Pin housing

Figure A-1. AMP Multilock Connector

Removing Terminals from Housing

See

Figure A-2

. Bend back the latch (1) to free one end

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

Look in the terminal side of the connector (opposite the
secondary lock) and note the cavity next to each terminal.

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.

Press the tang in the housing to release the terminal.

Socket: Lift the socket tang (8) up.

Pin: Press the pin tang (7) down.

NOTE

A "click" is heard if the tang is released.

Gently tug on wire to pull wire and terminal from cavity.

HOME

2009 Dyna Service: Appendix A Connector Repair A-1

sm00013

Latch

Secondary lock open

Pin housing

Socket housing

Pin terminal

Socket terminal

Tang (pin)

Tang (socket)

Figure A-2. AMP Multilock Connector: Socket and Pin

Housings

Inserting Terminals into Housing

NOTE

See

Figure A-3

. Cavity numbers are stamped into the sec-

ondary locks of both the socket and pin housings. Match the
wire color to the cavity number found on the wiring diagram.

Hold the terminal so the catch faces the tang in the
chamber. Insert the terminal into its numbered cavity until
it snaps in place.

NOTES

•

Up and down can be determined by the position of the
release button, the button is the top of the connector.

•

On the pin side of the connector, tangs are positioned at
the bottom of each cavity, so the slot in the pin terminal
(on the side opposite the crimp tails) must face downward.

•

On the socket side, tangs are at the top of each cavity, so
the socket terminal slot (on the same side as the crimp
tails) must face upward.

Gently tug on wire end to verify that the terminal is locked
in place.

Rotate the hinged secondary lock inward until tabs fully
engage latches on both sides of connector.

– AMP

sm00005

3-place housing

6-place housing

10-place housing

Figure A-3. AMP Multilock Connector: Cavity Numbers on

Secondary Locks (Socket Housings Shown)

Preparing Wire Leads for Crimping

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

HOME

A-2 2009 Dyna Service: Appendix A Connector Repair

See

Figure A-4

and

Figure A-5

. Select the pin/socket ter-

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).

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

NEST

WIRE GAUGE

Front

Middle

Rear

sm00004

Insulation crimp tail

Wire crimp tail

Locking bar groove

Figure A-4. AMP Multilock Connector: Pin Terminal

sm00001

Insulation crimp tail

Wire crimp tail

Locking bar groove

Figure A-5. 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.

See

Figure A-6

. Squeeze the handles to cycle the AMP

MULTILOCK CRIMPER (Part No. HD-41609) to the fully
open position (1).

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

NOTE

See

Figure A-4

and

Figure A-5

. 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.

See

Figure A-6

. 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.

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.

Insert stripped end of lead (5) until ends make contact with
locking bar.

Verify that wire is positioned so that wire crimp tails
squeeze bare wire strands, while insulation crimp tails fold
over the wire lead insulation.

Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is com-
plete.

Raise up locking bar (7) and remove crimped terminal.

HOME

2009 Dyna Service: Appendix A Connector Repair A-3

sm00007

Open position

Locking bar flange

Insert contact

Release locking bar

Insert lead

Squeeze

Raise locking bar

Remove crimped terminal

Figure A-6. AMP Multilock Connector: Terminal Crimping

Procedure

Inspecting Crimped Terminals

See

Figure A-7

. Inspect the wire core crimp (2) and insulation

crimp (1). Distortion should be minimal.

sm00008

Insulation crimp

Wire core crimp

Figure A-7. AMP Multilock Connector: Terminal Crimp

HOME

A-4 2009 Dyna Service: Appendix A Connector Repair

A.2

AUTOFUSE ELECTRICAL CONNECTORS

AUTOFUSE CONNECTOR REPAIR

TOOL NAME

PART NUMBER

SNAP-ON TERMINAL PICK

GA500A

General

Autofuse electrical connector terminals are found in ignition
switches and some fuse blocks.

Disassembly

Obtain SNAP-ON TERMINAL PICK (Part No. GA500A).

See

Figure A-8

Figure A-9

. Insert smallest pair of pins

into chamber on mating end of socket housing to depress
tangs on each side of terminal simultaneously.

Gently pull on wire to remove terminal from wire end of
socket housing.

If necessary, crimp new terminals on wires.

Assembly

Using a thin flat blade, like that on a hobby knife, carefully
bend tang on each side of terminal outward away from
terminal body.

With the open side of the terminal facing rib on wire end
of socket housing, insert terminal into chamber until it locks
in place.

sm02849

Figure A-8. Removing Autofuse Terminal from Ignition

Switch

sm03480

Figure A-9. Removing Autofuse Terminal from Fuse Block

HOME

2009 Dyna Service: Appendix A Connector Repair A-5

A.3

DELPHI CONNECTORS

DELPHI CONNECTOR REPAIR

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 PACKARD 150 METRI-PACK

CONNECTORS

to remove/install terminals in this connector.

See

Figure A-11

. If present, free one side of wire lock (1)

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.

Use a fingernail to pry colored terminal lock (2) loose and
then remove from mating end of socket housing.

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.

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.

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.

Install colored terminal lock onto mating end of socket
housing.

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.

sm00014

Figure A-10. Delphi Connector: Socket Housing Latch

HOME

A-6 2009 Dyna Service: Appendix A Connector Repair

sm00015

Remove wire lock

Remove terminal lock

Pry tang outward

Figure A-11. Delphi Connector: Removing Socket

Terminals

HOME

2009 Dyna Service: Appendix A Connector Repair A-7

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