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Harley Davidson 2011 Touring Models. Electrical Diagnostic Manual - page 23

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Figure A-12. Delphi 800 Metri-Pack Sealed Main Fuse

Housing: Bend Tang

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A-10 2011 Touring Diagnostics: Appendix A Connector Repair

A.8

DELPHI METRI-PACK TERMINAL REPAIR

METRI-PACK TERMINAL CRIMPS

TOOL NAME

PART NUMBER

PACKARD TERMINAL CRIMP TOOL

HD-38125-6

PACKARD TERMINAL CRIMPER

HD-38125-7

PACKARD CRIMPING TOOL

HD-38125-8

Matching Terminal To Crimper

Metri-Pack connectors embossed with the initials P.E.D. require
Packard crimp tools to crimp terminals to wire leads.

Terminals are crimped twice to a wire lead, once over the wire
core and a second time over the insulation/seal.

See

Figure A-13

. A completed crimp may require two different

crimping dies found on PACKARD TERMINAL CRIMP
TOOL (Part No. HD-38125-6) and/or PACKARD TERMINAL
CRIMPER (Part No. HD-38125-7). The terminal (pin or socket)
and the wire lead gauge will determine the core crimp die and
the insulator/seal die.

NOTE

The PACKARD CRIMPING TOOL (Part No. HD-38125-8) will
also crimp sealed splice connectors in wire gauge sizes 18-20,
14-16 and 10-12.

Preparing Wire Lead

Use a wire striper to strip off the insulation and expose 5/32
in. (4.0 mm) of wire core.

Crimping Wire Core

NOTE

Metri-Pack terminal crimps require two steps. Always perform
Crimping Wire Core before Crimping Insulation/Seal.

Squeeze and release handles until ratchet automatically
opens.

Identify the corresponding sized nest for the core crimp.

Position the core crimp in the die. Be Sure the core crimp
tails are facing the forming jaws.

Gently squeeze the handles until crimpers just secure the
core crimp tails.

Insert stripped wire between crimp tails. Verify that wire
is positioned so that short pair of crimp tails squeeze core
wire strands, while long pair is positioned over the insula-
tion or seal material.

Squeeze handles tightly closed. Release grip and the tool
will automatically open.

sm00035

HD-38125-6 sealed terminals

HD-38125-7 non-sealed terminals

HD-38125-8 non-sealed terminals

Figure A-13. Metri-Pack Terminal Crimp Tools

Crimping Insulation/Seal

NOTE

Always perform Crimping Wire Core before Crimping Insu-
lation/Seal.

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2011 Touring Diagnostics: Appendix A Connector Repair A-11

See

Figure A-14

. Identify the correct die for the insula-

tion/seal crimp (2).

Position the insulation/seal crimp in the nest. Be sure the
insulation/seal crimp tails are facing the forming jaws.

Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimp is complete.

Inspecting Crimps

See

Figure A-14

. Inspect the wire core crimp (1). The tails

should be folded in on the wire core without any distortion
or excess wire strands.

Inspect the insulation (2) or seal (3) crimp. The tails of the
terminal should be wrapped around the insulation without
distortion.

sm00036

Wire core crimp

Insulation crimp

Seal crimp

Figure A-14. Metri-Pack Connector: Inspect Core and

Insulation/Seal Crimps

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A-12 2011 Touring Diagnostics: Appendix A Connector Repair

A.9

DELPHI MICRO 64 SEALED CONNECTORS

DELPHI MICRO 64 SEALED CONNECTOR
REPAIR

TOOL NAME

PART NUMBER

TERMINAL REMOVER

HD-45928

TERMINAL CRIMPER

HD-45929

General

Delphi Micro 64 Sealed connectors are frequently found on
speedometers, tachometers and the ECM of Touring Models.

Separating Pin and Socket Housings

Bend back the external latches slightly and separate the pin
and socket housings.

Mating Pin and Socket Housings

Orient the wire lead colors and push the pin and socket hous-
ings of the connector together until the latches click.

Removing Terminal

See

Figure A-15

. Locate the head of the secondary lock

(1) on one side of the connector housing.

Insert the blade of a small screwdriver between the center
ear of the lock and the connector housing and gently pry
out lock. When partially removed, pull lock from connector
housing.

Locate pin hole (2) between terminals on mating end of
connector.

9 10

11 12

sm00047

Secondary lock

Pin hole

Stamped number

Figure A-15. Delphi Micro-64 Sealed Connector: Housing

See

Figure A-16

. Obtain the TERMINAL REMOVER (Part

No. HD-45928).

See

Figure A-17

. Push the adjacent terminals all the way

into the connector housing and then insert tool into hole
until it bottoms.

Leaving the tool installed, gently tug on wires to pull either
one or both terminals from wire end of connector. Remove
tool.

sm00046

Figure A-16. Terminal Remover (HD-45928)

sm00048

Figure A-17. Delphi Micro-64 Sealed Connector: Insert Tool

and Remove Terminal

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2011 Touring Diagnostics: Appendix A Connector Repair A-13

Installing Terminal

Insert terminal into its respective numbered chamber on
wire end of connector. No special orientation of the ter-
minal is necessary.

NOTE

See

Figure A-15

. For wire location purposes, the corners of

the socket housing are stamped (3) with the numbers 1, 6, 7
and 12, representing terminals 1-6 on one side, and 7-12 on
the other.

Bottom the terminal in the chamber and then gently tug
on the wire to verify that it is locked in place.

NOTE

Once the terminal is removed it may not lock in place when
first installed. Until the lock engages, move the terminal back
and forth slightly while wiggling the lead.

Since the terminal remover tool releases two terminals
simultaneously, repeat step 2 on the adjacent terminal
even if it was not pulled from the connector housing.

With the center ear on the head of the secondary lockpin
facing the mating end of the connector, push secondary
lock in until head is flush with the connector housing.

Preparing Wire Leads for Crimping

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

Crimping Terminals

Inspect new socket terminal for bent or deformed contact
and crimp tails. Replace as necessary.

See

Figure A-19

. Squeeze the handles of the TERMINAL

CRIMPER (Part No. HD-45929) to cycle the tool to the
fully open position (1).

Raise locking bar and barrel holder by pushing up on
bottom tab with index finger (2).

With the crimp tails facing upward, insert terminal through
locking bar into front hole in barrel holder (20-22 gauge
wire) (3).

Release locking bar to lock position of contact. When
correctly positioned, the locking bar fits snugly in the space
at the front of the core crimp tails and the closed side of
the terminal rests on the outer nest of the crimp tool.

Insert wires between crimp tails until ends make contact
with locking bar. Verify that wire is positioned so that wide
pair of crimp tails squeeze bare wire strands, while the
narrow pair folds over the insulation material.

Squeeze handle of crimp tool until tightly closed (4). Tool
automatically opens when the crimping sequence is com-
plete.

Raise locking bar and barrel holder to remove contact.

Inspecting Crimps

Inspect the quality of the core and insulation crimps. Distortion
should be minimal.

sm00045

Figure A-18. Terminal Crimper (HD-45929)

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A-14 2011 Touring Diagnostics: Appendix A Connector Repair

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Open position

Raising locking bar

Insert terminal

Crimp terminal

Figure A-19. Delphi Micro-64 Sealed Connector: Terminal

in Crimper

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2011 Touring Diagnostics: Appendix A Connector Repair A-15

A.10

DELPHI GT 150 SEALED CONNECTORS

DELPHI GT 150 SEALED CONNECTOR
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-20

. 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.

See

Figure A-21

. 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-20. Delphi GT 150 Sealed Connector: Socket

Housing Latch

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A-16 2011 Touring Diagnostics: Appendix A Connector Repair

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Remove wire lock

Remove terminal lock

Pry tang outward

Figure A-21. Delphi GT 150 Sealed Connector: Removing

Socket Terminals

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2011 Touring Diagnostics: Appendix A Connector Repair A-17

A.11

DELPHI GT 280 SEALED 73-TERMINAL ECM
CONNECTOR

NOTE

Do not operate latch lever when connector is not mated to
ECU. Damage will occur.

Separating Socket Housing From ECM

NOTE

Although this procedure shows the ECM removed, the ECM
connector can be removed and installed with the ECM removed
or in place.

See

Figure A-22

. Remove strap. While pressing latch (1), rotate

lock lever to the released position (2).

Mating Socket Housing To ECM

Push the connector into the ECM and rotate lock lever to the
locked position.

Socket Terminal

Cut cable strap to release harness from strain relief collar
of connector housing.

See

Figure A-23

. Release latches (4) that retain cover (3)

to housing (2) and remove cover.

Follow instructions in

A.9 DELPHI MICRO 64 SEALED

CONNECTORS

to remove and service the Micro-64 ter-

minals.

Install connector housing cover. Verify all wires are within
the confines of the cover and that the cover latches are
engaged.

Install new cable strap cable to the strain relief of the
connector.

ECM Ground Terminal

See

Figure A-23

. Remove secondary lock (1).

See

Figure A-24

. Using a thin blade screwdriver, gently

pry ground terminal retainer from connector housing.

See

Figure A-25

. Using a thin blade screwdriver, release

latch and pull ground wire, wire seal and terminal from
cover side of housing.

Follow instructions in

A.8 DELPHI METRI-PACK TER-

MINAL REPAIR

to replace the terminal or wire seal.

Push the terminal into place from the cover side of the
connector housing until the latch engages. Pull on wire to
verify terminal is secure.

NOTE

Secondary lock has one short leg and one long leg. Be sure
to install correctly as shown in

Figure A-23

See

Figure A-23

. Install ground secondary lock (5) and

install secondary lock (1) as shown.

sm06098

Latch

Lock lever released

Figure A-22. Unlatch ECM Connector

sm06093

Secondary lock

Terminal housing

Cover

Cover latch

Ground secondary lock

Figure A-23. Delphi 73-Terminal ECM Connector

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A-18 2011 Touring Diagnostics: Appendix A Connector Repair

sm06094

Figure A-24. Remove Ground Secondary Lock

sm06095

Figure A-25. Remove ECM Ground Terminal

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2011 Touring Diagnostics: Appendix A Connector Repair A-19

A.12

DEUTSCH DT SEALED CONNECTORS

DEUTSCH DT SEALED CONNECTOR
REPAIR

TOOL NAME

PART NUMBER

DEUTSCH TERMINAL REPAIR KIT

HD-41475

FLAT BLADE L-HOOK

HD-41475-100

General

Deutsch DT Sealed 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 connectors, including those associated with
right side accessories, are black.

NOTE

A DEUTSCH TERMINAL REPAIR 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-26

. To separate the connector halves, Press the

external latch(es) (1) on the socket housing (2) while rocking
the pin (3) and socket housings.

NOTES

•

Generally, the socket housing is found on the accessory
side, while the pin housing is plumbed to the wiring har-
ness.

•

Two-, three-, four- and six-place Deutsch connectors have
one latch on the connector.

•

Eight- and twelve-place connectors have a latch on each
side. Simultaneously press both latches to separate the
connector.

Mating Pin and Socket Housings

Align the connectors to match the wire lead colors.

For One External Latch: Two-, three-, four- and six-
place Deutsch connectors have one external latch on
the socket half of the connector. To fit the halves of
the connector together, the latch on the socket side
must be aligned with the latch cover on the pin side.

For Two External Latches: (8-place and 12-place)
Align the tabs on the socket housing with the grooves
on the pin housing.

Insert socket housing into pin housing until it snaps or
clicks into place.

For Two External Latches: (8-place and 12-place) If
latches do not click (latch), press on one side of the con-
nector until that latch engages, then press on the opposite
side to engage the other latch.

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

Place large end of slot on attachment clip over T-stud on
frame. Push assembly forward to engage small end of
slot.

sm00017

External latch

Socket housing

Pin housing

Figure A-26. Deutsch DT Sealted Connector

Removing Socket Terminals

See

Figure A-27

. Insert a small screwdriver between the

socket housing and locking wedge in-line with the groove
(in-line with the pin holes if the groove is absent). Turn the
screwdriver 90 degrees to pop the wedge up and remove
the secondary locking wedge.

See

Figure A-30

. Use a pick or small screwdriver to Press

terminal latches inside socket housing and back out
sockets through holes in rear wire seal.

NOTE

If wire leads require new terminals, see the instructions for
crimping terminals.

Installing Socket Terminals

Match wire lead color to connector cavity.

See

Figure A-29

. Fit rear wire seal (1) into back of socket

housing (2), if removed.

Grasp wire lead (3) approximately 1.0 in. (25.4 mm) behind
the socket terminal. Gently push socket through hole in
wire seal into its chambers until it "clicks" in place.

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

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A-20 2011 Touring Diagnostics: Appendix A Connector Repair

NOTE

Seal plugs (6) are installed through the wire seals of unused
chambers. If removed, seal plugs must be replaced to seal the
connector.

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

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-28

. 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.

sm00009

Figure A-27. Deutsch DT Sealed Connector: Remove

Secondary Locking Wedge

sm00018

Arrow on socket locking wedge

Arrow on pin locking wedge

Figure A-28. Deutsch DT Sealed Connector: 3-Place

Locking Wedges

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2011 Touring Diagnostics: Appendix A Connector Repair A-21

DEUTSCH

sm00010

Wire seal

Socket housing

Wire lead

Internal seal

Secondary locking wedge

Seal plug

Figure A-29. Deutsch DT Sealed Connector: 2, 3, 4 and

12-Place Socket Housings

Removing Pin Terminals

Use the hooked end of a stiff piece of mechanics wire, a
needle nose pliers or the FLAT BLADE L-HOOK (Part
No. HD-41475-100) to remove the secondary locking
wedge.

Gently Press terminal latches inside pin housing and back
out pins through holes in wire seal.

NOTES

•

If wire leads require new terminals, see the instructions
for crimping terminals.

•

If it should become necessary to replace a pin or socket
housing, note that the 8-place and 12-place gray and black
connectors are not interchangeable. Since location of the

alignment tabs differ between the black and gray con-
nectors, plugs or receptacles must be replaced by those
of the same color.

•

When replacing both socket and pin housings, then the
black may be substituted for the gray. The socket and pin
housings of all other connectors are interchangeable, that
is, the black may be mated with the gray, since the align-
ment tabs are absent and the orientation of the external
latch is the same.

sm00019

Figure A-30. Deutsch DT Sealed Connector: Depress

Terminal Latch and Back Out Pin

Installing Pin Terminals

See

Figure A-31

. Fit wire seal (1) into back of pin housing

(2).

Grasp wire lead approximately 1.0 in. (25.4 mm) behind
the pin terminal (3). Gently push pin through holes in wire
seal into its respective numbered chamber until it "clicks"
in place.

NOTE

A tug on the wire lead will confirm that a pin is locked in place.

Insert tapered end of secondary locking wedge (4) into
pin housing and press down until it snaps in place.

NOTES

•

The wedge fits in the center groove of the pin housing and
holds the terminal latches tightly closed.

•

See

Figure A-28

. 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
(2) 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 pin housing. The lock indicates when ter-
minals are not properly installed by not entering its fully
installed position.

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A-22 2011 Touring Diagnostics: Appendix A Connector Repair

DEUTSCH

sm00020

Wire seal

Pin housing

Pin terminal

Locking wedge

Figure A-31. Deutsch DT Sealed Connector: 2, 3, 4 and

12-Place Pin Housings

Crimping Terminals

Identify which of the types of Deutsch terminals are used with
the connector and follow the corresponding crimping instruc-
tions. Refer to

Table A-1

Table A-1. Deutsch Connector: Terminal Crimping Instructions

CRIMPING INSTRUCTIONS

TYPE

A.13 DEUTSCH DT SEALED TERMINAL REPAIR

DT Sealed (with crimp tails)

A.15 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR

DTM Mini Sealed Terminal (solid
barrel)

A.14 DEUTSCH DTM SEALED MINI TERMINAL REPAIR

DTM Mini Sealed Terminal (with crimp
tails)

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2011 Touring Diagnostics: Appendix A Connector Repair A-23

A.13

DEUTSCH DT SEALED TERMINAL REPAIR

DEUTSCH DT SEALED TERMINAL CRIMPS

TOOL NAME

PART NUMBER

DEUTSCH TERMINAL CRIMP TOOL

HD-39965-A

Preparing Wire Leads for Crimping

Use a shop gauge to determine gauge of wire lead.

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

Crimping Terminal to Lead

See

Figure A-32

. Squeeze the handles of the DEUTSCH

TERMINAL CRIMP TOOL (Part No. HD-39965-A) to open
the jaws. Push the locking bar (1) up.

Insert (2) terminal (socket/pin) through hole of the locking
bar, so that the rounded side of the contact barrel rests in
the nest (concave split level area) with the crimp tails
facing upward. To match the wire gauge to the crimp tool
die, refer to

Table A-2

Release locking bar to lock terminal in die.

NOTE

If the crimp tails are slightly out of vertical alignment, the crimp
tool automatically rotates the terminal so that the tails face

straight upward. When positioned, the locking bar fits snugly
in the space between the contact band and the core crimp tails.

Insert stripped wire core between crimp tails until ends
make contact with locking bar. Verify that wire is positioned
so that short pair of crimp tails squeeze bare wire strands,
while long pair folds over the insulation.

Squeeze handle of crimp tool until tightly closed. Tool
automatically opens after the terminal is crimped.

Raise locking bar up and remove wire lead and terminal.

Inspecting Crimps

Inspect the wire core and insulation crimps. Distortion should
be minimal.

Table A-2. Deutsch DT Sealed Terminal Crimp:Wire Gauge

To Die

CRIMP TOOL DIE

WIRE GAUGE (AWG)

Front

Middle

16-18

sm00021

Insert stripped lead

Open jaws and raise locking bar

Insert terminal in locking bar

Squeeze crimper

Raise locking bar and remove terminal

Release locking bar to lock terminal in die

Figure A-32. Crimping a Deutsch DT Sealed Terminal

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A-24 2011 Touring Diagnostics: Appendix A Connector Repair

A.14

DEUTSCH DTM SEALED MINI TERMINAL
REPAIR

DEUTSCH DTM SEALED MINI TERMINAL
CRIMPS

TOOL NAME

PART NUMBER

PACKARD TERMINAL CRIMPER

HD-38125-7

Preparing Wire Leads for Crimping

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

Crimping a Mini Terminal to Wire Lead

See

Figure A-33

. 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.

Position the core crimp on die E (1) of the crimper. Be
sure the core crimp tails are facing the forming jaws.

Gently apply pressure to handles of tool until crimpers just
secure the core crimp tails.

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.

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).

Position the insulation crimp on nest C of the crimper. Be
sure the insulation crimp tails are facing the forming jaws.

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

Inspecting Crimps

Inspect the core and insulation crimps. Distortion should be
minimal.

sm00022

E die

Crimper ratchet trigger

Figure A-33. Packard Terminal Crimper (HD-38125-7)

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2011 Touring Diagnostics: Appendix A Connector Repair A-25

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