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Harley Davidson 2011 Touring Models. Electrical Diagnostic Manual - page 24

A.15

DEUTSCH DTM SEALED SOLID BARREL MINI
TERMINAL REPAIR

DEUTSCH DTM SEALED SOLID BARREL
TERMINAL CRIMPS

TOOL NAME

PART NUMBER

ELECTRICAL CRIMPER TOOL

HD-42879

Preparing Wire Leads For Crimping

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

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

Adjusting Crimper Tool

See

Figure A-34

. Squeeze the ELECTRICAL CRIMPER

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

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

Raise selector knob and rotate until selected wire size
stamped on wheel is aligned with "SEL. NO." arrow (3).

Loosen knurled locknut (4) and turn adjusting screw (5)
clockwise (in) until it stops.

Crimping a Barrel Contact To Wire Lead

See

Figure A-35

. Turn tool over and drop contact barrel

(1) into indentor cover (2) hole with the wire end out.

Turn adjusting screw counterclockwise (out) until contact
is flush with bottom of depression in indentor cover.
Tighten knurled locknut.

Slowly squeeze handles of crimp tool until contact is
centered between the four indentor points (3).

Insert bare wire core strands of stripped wire lead (4) into
contact barrel. Squeeze handle of crimp tool until tightly
closed. Tool automatically opens when the crimping
sequence is complete.

Remove wire lead with crimped contact from indentor.

NOTE

Tool must be readjusted when changing contact size/type.

Install pin to lock selector knob.

Inspecting Crimps

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

This

HAND

tool

ust

not

used

ered

"PRESS''

defined

OSHA

CFR

1910.211

(46)

sm00023

Locking pin

Selector knob

SEL. NO. arrow

Knurled locknut

Adjusting screw

Figure A-34. Electrical Crimper Tool (HD-42879)

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A-26 2011 Touring Diagnostics: Appendix A Connector Repair

HDT

- 48

- 00

JDG360-1

HEMET

RYAN

AIRPOR

T, P

. BO

X 878

HEMET

, CA.

92343-0161

(714)

929-1200

INDUSTRIAL

ODUCTS

DIVISION

HDT

- 48

- 00

JDG360-1

HEMET

RYAN

AIRPOR

T, P

. BO

X 878

HEMET

, CA.

92343-0161

(714)

929-1200

INDUSTRIAL

ODUCTS

DIVISION

sm00024

Contact barrel

Indentor cover

Indentor point

Stripped wire lead

Figure A-35. Deutsch Solid Barrel

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2011 Touring Diagnostics: Appendix A Connector Repair A-27

A.16

JAE MX19 SEALED CONNECTORS

TOOL NAME

PART NUMBER

TERMINAL EXTRACTOR

B-50085

Connector Housings

Separate Housings: See

Figure A-36

. Press the two release

buttons on each side of the housing to separate the connector.

Connect Housings: Align and press the housings together
until the locking tabs click.

sm06925

Figure A-36. Release Buttons: JAE MX19 Sealed Connector

Removing Terminals

Modify a TERMINAL EXTRACTOR (Part No. B-50085)
by filing the front edge to 45 degrees.

See

Figure A-37

. Insert the extractor (1) into the opening

above the terminal and press the plastic molding (2) up
and out of the way.

Pull the wire lead and terminal out of the back of the
housing.

Installing Terminals

Inspect the plastic molding and replace the connector
housing if necessary.

Orient the terminal to the housing and push terminal into
the housing until it snaps into place.

sm06926

Extractor tool

Molding

Figure A-37. JAE MX19 Terminal Removal

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A-28 2011 Touring Diagnostics: Appendix A Connector Repair

A.17

MOLEX CMC SEALED CONNECTORS

Separating the Connector

Release: See

Figure A-38

. Press the catch and rotate the lever

arm down.

Connect: Press on the front guard to release the latch and
rotate the lever arm up until the catch clicks in place.

sm06931

Figure A-38. Release

Removing Terminals

With the lever arm open, cut the cable strap around the
wire bundle.

See

Figure A-39

. Open a wire cap latch with a small

screwdriver (1).

Maintain pressure on the cap and open the opposite latch
with the screw driver (2).

Slide the cap off (3).

See

Figure A-40

. Use the screwdriver to open the sec-

ondary lock. Pull the locking bar all the way out.

See

Figure A-41

. Locate the wire lead cavity by the alpha-

numeric coordinates.

See

Figure A-42

. Insert the pins of the CMC extractor tool

(1) into the access slots (2) of the terminal cavity and
retract the lead and terminal.

Installing Terminals

Orient the terminal to the housing cavity and snap the
terminal in place.

Slide the cap over the lead bundle and snap the cap in
place.

Install a cable strap through the guide and around the lead
bundle.

sm06936

Press latch

Press cap and latch

Remove cap

Figure A-39. Remove the Wire Lead Cap

sm06928

Figure A-40. Molex CMC Sealed Connector Secondary

Lock

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2011 Touring Diagnostics: Appendix A Connector Repair A-29

sm06927

Alpha

Numeric

Figure A-41. Alpha - Numeric Coordinates

sm06935

Extractor tool

Access slots

Figure A-42. Terminal Removal

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A-30 2011 Touring Diagnostics: Appendix A Connector Repair

A.18

MOLEX MX 150 SEALED CONNECTORS

MOLEX MX 150 SEALED CONNECTOR
REPAIR

TOOL NAME

PART NUMBER

TERMINAL REMOVER

HD-48114

Separating Pin and Socket Housings

See

Figure A-43

. Press the latch while pulling the pin and

socket housings apart.

Mating Pin and Socket Housings

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.

Press the housings together until the latch clicks.

Removing Terminals

Pull the secondary lock up, approximately 3/16 in. (4.8
mm), until it stops.

Socket Housing: See

Figure A-44

. Use a small

screwdriver in the pry slot. The slot next to the
external latch provides a pivot point.

Pin Housing: See

Figure A-45

. Use needle nose

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.

See

Figure A-46

. Insert TERMINAL REMOVER (Part

No. HD-48114) into the pin hole next to the terminal until
the tool bottoms.

Socket Housing: The pin holes are inside the ter-
minal openings.

Pin Housing: The pin holes are outside the pins.

Pressing the terminal remover to the bottom of the pin
hole, gently pull on the wire to remove wire terminal from
its cavity.

Installing Terminals

See

Figure A-47

. 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. The cavity number can be determined by
counting the cavities up or down along the row from each
stamped number.

Orient the terminal so that the tang (2) opposite the open
crimp engages the slot (3) in the cavity.

Push the terminal into the cavity.

Gently tug on wire to verify that the terminal is captured
by the secondary lock.

With all terminals installed, push the secondary lock into
the socket housing to lock the wire terminals into the
housing.

sm00040

Figure A-43. Molex MX 150 Sealed Connector: Latch

sm03332

Figure A-44. Secondary Lock Pry Slot (Socket Housing)

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2011 Touring Diagnostics: Appendix A Connector Repair A-31

sm02851

Figure A-45. Pull Up Secondary Lock (Pin Housing)

sm00043

Figure A-46. Molex MX 150 Sealed Connector: Terminal

Remover (HD-48114)

sm00044

Cavity number

Tang

Cavity slot

Figure A-47. Molex MX 150 Sealed Connector: Pin Cavities

and Wire Terminal

CRIMP TERMINAL TO LEAD

TOOL NAME

PART NUMBER

TERMINAL CRIMPER

HD-48119

Prepare Lead

Cut the damaged terminal close to the back of the terminal
to leave as much wire length as possible.

Strip approximately 3/16 in. (4.70-5.60 mm) of insulation
from the end of the wire lead.

NOTE

The strip length is the same for both pin and socket terminals
and for wire gauges from 22 to 14.

Prepare Tool

Identify the punch/die in the jaws of the TERMINAL
CRIMPER (Part No. HD-48119) for the wire gauge. Refer
to

Table A-3

Squeeze and release the handles to open the tool.

NOTE

The crimp tool automatically opens when the handles are
released.

See

Figure A-48

. 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.

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A-32 2011 Touring Diagnostics: Appendix A Connector Repair

Table A-3. Crimp Tool Wire Gauge Punch/Die

PUNCH/DIE

AWG (WIRE GAUGE)

Left

Middle

18-20

Right

14-16*

* Crimp 16 AWG pin terminals in the 18-20 middle die.

sm02853

Figure A-48. Open Terminal Crimper (HD-48119) at 45

Degrees

sm02854

Socket locator bar

Pin locator bar

Figure A-49. Terminal Locator Bars

Position Terminal in the Punch/Die

See

Figure A-50

. With the crimp tails up, place the terminal

through the punch/die into the square opening in the
socket locator bar.

Socket Terminal: See

Figure A-49

. A socket terminal

stops against the back face of the socket locator bar
(1).

Pin Terminal: See

Figure A-51

. 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.

See

Figure A-52

. Ratchet the handles together until the

crimp tails are held in vertical alignment between the punch
and the die.

sm02855

Figure A-50. Square Openings in Socket Locator Bar

Insert Stripped Lead

See

Figure A-53

. 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.

NOTES

•

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.

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2011 Touring Diagnostics: Appendix A Connector Repair A-33

sm02856

Figure A-51. Pin Terminal against Pin Locator Bar

sm02857

Figure A-52. Crimp Tails in Vertical Alignment between

Punch and Die

Crimp Terminal to Lead

Holding the wire lead in position touching the locator face
at an angle, quickly and smoothly squeeze the crimp tool
closed.

Final squeeze the handles to open the tool and release
the terminal.

NOTE

A stuck or jammed tool can be opened by pressing the ratchet
release lever found between the handles. Do not force the
handles open or closed.

sm02858

Figure A-53. Stripped Lead at Up Angle

Inspect Crimp

Inspect Crimp: Inspect the core and insulation crimp.

See

Figure A-54

. The core tails should be creased

into the wire strands at the core crimp (1).

Strands (2) of wire should be visible beyond the core
crimp but not forward into the terminal shell.

The insulation tails should be folded into the insulation
(3) without piercing or cutting the insulation.

Distortion should be minimal.

Test Crimp: Hold the terminal and pull the lead.

sm02859

Core crimp

Wire strands

Insulation crimp

Figure A-54. Terminal Crimp

HOME

A-34 2011 Touring Diagnostics: Appendix A Connector Repair

A.19

TYCO 070 MULTILOCK UNSEALED CONNECTOR

TYCO 070 MULTILOCK UNSEALED
CONNECTOR REPAIR

TOOL NAME

PART NUMBER

AMP MULTI-LOCK CRIMPER

HD-41609

SNAP-ON PICK

SNAP-ON TT600-3

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-55

. 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 MULTI-LOCK
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-55

. Press 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-55. Tyco 070 Multilock Unsealed Connector

Removing Terminals from Housing

See

Figure A-56

. 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. SNAP-ON 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.

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2011 Touring Diagnostics: Appendix A Connector Repair A-35

sm00013

Latch

Secondary lock open

Pin housing

Socket housing

Pin terminal

Socket terminal

Tang (pin)

Tang (socket)

Figure A-56. Tyco 070 Multilock Unsealed Connector:

Socket and Pin Housings

Inserting Terminals into Housing

NOTE

See

Figure A-57

. 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-57. Tyco 070 Multilock Unsealed 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-36 2011 Touring Diagnostics: Appendix A Connector Repair

. Select the pin/socket

terminals 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-4

Table A-4. 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-58. Tyco 070 Multilock Unsealed Connector: Pin

Terminal

sm00001

Insulation crimp tail

Wire crimp tail

Locking bar groove

Figure A-59. Tyco 070 Multilock Unsealed Connector:

Socket Terminal

Crimping Terminals to Leads

NOTE

Crimping with the AMP Multi-lock Crimper is a one step opera-
tion. One squeeze crimps both the wire core and the insulation
tails.

See

Figure A-60

. Squeeze the handles to cycle the AMP

MULTI-LOCK 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-58

and

Figure A-59

. 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-60

. 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

2011 Touring Diagnostics: Appendix A Connector Repair A-37

sm00007

Open position

Locking bar flange

Insert contact

Release locking bar

Insert lead

Squeeze

Raise locking bar

Remove crimped terminal

Figure A-60. Tyco 070 Multilock Unsealed Connector:

Terminal Crimping Procedure

Inspecting Crimped Terminals

See

Figure A-61

. Inspect the wire core crimp (2) and insulation

crimp (1). Distortion should be minimal.

sm00008

Insulation crimp

Wire core crimp

Figure A-61. Tydo 070 Multilock Unsealed Connector:

Terminal Crimp

HOME

A-38 2011 Touring Diagnostics: Appendix A Connector Repair

A.20

SEALED SPLICE CONNECTORS

SEALED SPLICE CONNECTOR REPAIR

TOOL NAME

PART NUMBER

HEAT GUN

HD-25070

PACKARD CRIMPING TOOL

HD-38125-8

ULTRA TORCH

HD-39969

HEAT SHIELD ATTACHMENT

HD-41183

General

Splice connectors and several OE ring terminal connectors
use heat shrink covering to seal the connection.

Preparing Wire Leads

NOTE

If adjacent wires are to be spliced, stagger the splices so that
the sealed splice connectors will not touch each other but are
located at different positions along the length of the wires.

Using a shop gauge, identify the gauge of the wire.

Match the wire gauge to a sealed splice connector by color
and part number. Refer to

Table A-5

Using a wire stripper, cut and strip a length of insulation
off the wire ends. Refer to

Table A-5

for the strip length.

Table A-5. Sealed Splice Connectors

STRIP LENGTH

PART NO.

COLOR

WIRE GAUGE

3/8 in. (9.5 mm)

70585-93

Red

18-20

(0.5-0.8 mm)

3/8 in. (9.5 mm)

70586-93

Blue

14-16

(1.0-2.0 mm)

3/8 in. (9.5 mm)

70587-93

Yellow

10-12

(3.0-5.0 mm)

NOTE

If any copper wire strands are cut off of the wire core, trim the
end and strip the wire again in a larger gauge stripper.

Splicing Wire Leads

NOTE

See

Figure A-63

. The connector is crimped twice - one side

and then the other.

See

Figure A-62

. Open the PACKARD CRIMPING

TOOL (Part No. HD-38125-8) ratchet by squeezing the
handles closed.

Match the connector color to the wire gauge crimp die in
the jaws and insert one end of the sealed connector.

Gently squeeze the handles until the connector is held in
the jaws.

See

Figure A-63

. Feed the stripped end of a wire into the

connector until the wire stops inside the metal insert (1).

Squeeze the handles tightly closed to crimp the lead in
the insert (2). The tool automatically opens when the
crimping is complete.

Slide the connector to the other half of the metal insert.
Insert the stripped wire lead (1) until it stops, and crimp
the lead in the insert (2).

Be sure to follow manufacturer's instructions when using
the UltraTorch UT-100 or any other radiant heating device.
Failure to follow manufacturer's instructions can cause a
fire, which could result in death or serious injury. (00335a)

•

Avoid directing heat toward any fuel system component.
Extreme heat can cause fuel ignition/explosion resulting
in death or serious injury.

•

Avoid directing heat toward any electrical system com-
ponent other than the connectors on which heat shrink
work is being performed.

•

Always keep hands away from tool tip area and heat shrink
attachment.

Use an ULTRA TORCH (Part No. HD-39969), or a HEAT
GUN (Part No. HD-25070) with a HEAT SHIELD
ATTACHMENT (Part No. HD-41183), to heat the connector
from the center of the crimp (3) out to each end.

NOTE

It is acceptable for the splice to rest against the heat shrink
tool attachment.

Inspecting Seals

See

Figure A-63

. Allow the splice to cool and inspect the seal.

The insulation should appear smooth and cylindrical. Melted
sealant will have extruded out the ends (4) of the insulation.

HOME

2011 Touring Diagnostics: Appendix A Connector Repair A-39