Content .. 30 31 32 33 ..

Harley Davidson 2013 Sportster Models. Service Manual - page 32

A.10

DELPHI MICRO 64 SEALED CONNECTOR

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. Align pin and socket housings.
Push the pin and socket housings of the connector together
until the latches click.

Removing Terminal

See

Figure A-18

. 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

1. Secondary lock
2. Pin hole
3. Stamped number

Figure A-18. Delphi Micro-64 Sealed Connector: Housing

See

Figure A-19

. Obtain the TERMINAL REMOVER (Part

No. HD-45928).

See

Figure A-20

. 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-19. Terminal Remover (HD-45928)

sm00048

Figure A-20. Delphi Micro-64 Sealed Connector: Insert Tool

and Remove Terminal

HOME

2013 Sportster Service: 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-18

. 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 removed, the terminal 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 1/8 in (3.0 mm) of insulation from the wire lead.

Crimping Terminals

Inspect

new

socket terminal for bent or deformed contact

and crimp tails. Replace as necessary.

See

Figure A-22

. 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. Position wire that the 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-21. Terminal Crimper (HD-45929)

HOME

A-14 2013 Sportster Service: Appendix A Connector Repair

sm00049

1. Open position
2. Raising locking bar
3. Insert terminal
4. Crimp terminal

Figure A-22. Delphi Micro-64 Sealed Connector: Terminal

in Crimper

HOME

2013 Sportster Service: Appendix A Connector Repair A-15

A.11

DELPHI GT 150 SEALED CONNECTOR

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-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.

See

Figure A-24

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

from ear on wire end of socket housing. Release the other
side if necessary. Release wires from channels in wire
lock. Remove from socket housing.

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

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.

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, pre-
venting it from backing 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.

sm00014a

Figure A-23. Delphi GT 150 Sealed Connector: Socket

Housing Latch

HOME

A-16 2013 Sportster Service: Appendix A Connector Repair

sm00015a

1. Remove wire lock
2. Remove terminal lock
3. Pry tang outward

Figure A-24. Delphi GT 150 Sealed Connector: Removing

Socket Terminals

HOME

2013 Sportster Service: Appendix A Connector Repair A-17

A.12

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

See

Figure A-25

. Remove strap (1). Press the latch (2). Rotate

lock lever to the released position (3).

Mating Socket Housing To ECM

Push the connector into the ECM. Rotate the lock lever to the
locked position.

Socket Terminal

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

See

Figure A-26

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

to housing (2) and remove cover.

Remove and service the Micro-64 terminals. See

A.10 DELPHI MICRO 64 SEALED CONNECTOR

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-26

. Remove secondary lock (1).

See

Figure A-27

. Using a thin blade screwdriver, gently

pry ground terminal retainer from connector housing.

See

Figure A-28

. Using a thin blade screwdriver, release

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

Follow instructions in

A.9 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

See

Figure A-26

. Secondary lock has one short leg and one

long leg. Install as shown.

See

Figure A-26

. Install ground secondary lock (5) and

install secondary lock (1) as shown.

sm06098a

1. Strap
2. Latch
3. Lock lever released

Figure A-25. Unlatch ECM Connector

sm06093

1. Secondary lock
2. Terminal housing
3. Cover
4. Cover latch
5. Ground secondary lock

Figure A-26. Delphi 73-Terminal ECM Connector

HOME

A-18 2013 Sportster Service: Appendix A Connector Repair

sm06094a

Figure A-27. Remove Ground Secondary Lock

sm06095a

Figure A-28. Remove ECM Ground Terminal

HOME

2013 Sportster Service: Appendix A Connector Repair A-19

A.13

DEUTSCH DT SEALED CONNECTOR

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. DT connectors associated with

left

side accessories,

such as the front and rear

left

turn signals, are

gray

. All other

DT connectors are

black

NOTE

A DEUTSCH TERMINAL REPAIR KIT (Part No. HD-41475)
contains a selection of seals and seal plugs, locking wedges,
attachment clips and terminals.

Also included is a FLAT BLADE L-HOOK (Part No. HD-41475-
100) used to remove locking wedges, compartmented storage
box and carrying case.

Separating Pin and Socket Housings

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.

NOTES

•

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

•

Six-place and smaller 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:

Six-place and smaller

Deutsch connectors have one external latch on the
socket housing. To join the housings, align the latch
on the socket side with the latch cover on the pin side.

For Two External Latches:

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.

NOTE

For Two External Latches: If latches do not click (latch), press
on one side of the connector 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.

sm00017a

1. External latch
2. Socket housing
3. Pin housing

Figure A-29. Deutsch DT Sealed Connector

Removing Socket Terminals

See

Figure A-30

. 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-33

. 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-32

. 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.

NOTE

Install seal plugs (6) into 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

HOME

A-20 2013 Sportster Service: Appendix A Connector Repair

wedge fits into the center groove within the socket housing
and holds the terminal latches tightly closed.

NOTES

•

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.

sm00009a

Figure A-30. Deutsch DT Sealed Connector: Remove

Secondary Locking Wedge

sm00018

1. Arrow on socket locking wedge
2. Arrow on pin locking wedge

Figure A-31. Deutsch DT Sealed Connector: 3-Place

Locking Wedges

HOME

2013 Sportster Service: Appendix A Connector Repair A-21

DEUTSCH

sm00010

1. Wire seal
2. Socket housing
3. Wire lead
4. Internal seal
5. Secondary locking wedge
6. Seal plug

Figure A-32. 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.

•

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

Figure A-33. Deutsch DT Sealed Connector: Press Terminal

Latch and Back Out Pin

Installing Pin Terminals

See

Figure A-34

. 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. 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-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.

HOME

A-22 2013 Sportster Service: Appendix A Connector Repair

DEUTSCH

sm00020

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

Crimping Terminals

Identify which of the types of Deutsch terminals are used with
the connector. Follow the corresponding crimping instructions.
Refer to

Table A-2

Table A-2. Deutsch Connector: Terminal Crimping Instructions

CRIMPING INSTRUCTIONS

TYPE

A.14 DEUTSCH DT SEALED TERMINAL REPAIR

DT Sealed (with crimp tails)

A.16 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR

DTM Mini Sealed Terminal (solid
barrel)

A.15 DEUTSCH DTM SEALED MINI TERMINAL REPAIR

DTM Mini Sealed Terminal (with crimp
tails)

HOME

2013 Sportster Service: Appendix A Connector Repair A-23

A.14

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

Crimping Terminal to Lead

See

Figure A-35

. Squeeze the handles of the DEUTSCH

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

Match the wire gauge to the crimp tool die. Refer to

Table A-3

NOTE

Rest the rounded side of the contact barrel in the nest (concave
split level area) with the crimp tails facing up.

Insert (2) terminal (socket/pin) through hole of the locking
bar.

Release locking bar to lock terminal in die.

NOTE

If the crimp tails are slightly out of alignment, the crimp tool
rotates the terminal to face the tails 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. Position wire that the 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. Tool
automatically opens after the terminal is crimped.

Raise locking bar up to remove wire lead and terminal.

Inspecting Crimps

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

Table A-3. 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 to remove terminal

Release locking bar to lock terminal in die

Figure A-35. Crimping a Deutsch DT Sealed Terminal

HOME

A-24 2013 Sportster Service: Appendix A Connector Repair

A.15

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

Crimping a Mini Terminal to Wire Lead

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.

Position the core crimp on die E (1) of the crimper. Verify
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 that the 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, squeeze the ratchet trigger (2).

Position the insulation crimp on nest C of the crimper.
Verify 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

1. E die
2. Crimper ratchet trigger

Figure A-36. Packard Terminal Crimper (HD-38125-7)

HOME

2013 Sportster Service: Appendix A Connector Repair A-25

A.16

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 1/4 in (6.4 mm) of insulation from the wire lead.

Adjusting Crimper Tool

See

Figure A-37

. 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. Roate knob 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-38

. 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 recess in indentor cover. Tighten
knurled locknut.

Slowly squeeze handles of crimp tool until contact centers
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

Adjust the crimper tool for each contact/wire size.

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

1. Locking pin
2. Selector knob
3. SEL. NO. arrow
4. Knurled locknut
5. Adjusting screw

Figure A-37. Electrical Crimper Tool (HD-42879)

HOME

A-26 2013 Sportster Service: 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

PRODUCTS

DIVISION

HDT

- 48

- 00

JDG360-1

HEMET

RYAN

AIRPOR

T, P

. BO

X 878

HEMET

, CA.

92343-0161

(714)

929-1200

INDUSTRIAL

PRODUCTS

DIVISION

sm00024

1. Contact barrel
2. Indentor cover
3. Indentor point
4. Stripped wire lead

Figure A-38. Deutsch Solid Barrel

HOME

2013 Sportster Service: Appendix A Connector Repair A-27

A.17

JAE MX19 SEALED CONNECTOR

JAE MX19 SEALED CONNECTORS

TOOL NAME

PART NUMBER

TERMINAL EXTRACTOR

B-50085

Connector Housings

Separate Housings:

See

Figure A-39

. Press the two release

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

Connect Housings:

Align housings. Press together until the

locking tabs click.

sm06925

Figure A-39. 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-40

. 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. Push terminal into
housing until it clicks into place.

sm06926

1. Extractor
2. Plastic molding

Figure A-40. JAE MX19 Terminal Removal

CRIMPING TERMINALS

TOOL NAME

PART NUMBER

UNIVERSAL CRIMPER SET

HD-50120

HAND CRIMP FRAME

HD-50120-2

JAE DIE

HD-50120-6

Strip the wire insulation to specification. Refer to

Table A-4

Install the JAE DIE (Part No. HD-50120-6) in the handle
of the HAND CRIMP FRAME (Part No. HD-50120-2) of
the UNIVERSAL CRIMPER SET (Part No. HD-50120).

Place the

new

terminal in the specified nest.

Insert the wire to the wire stop. Crimp the terminal.

Inspect the crimped terminal.

Table A-4. JAE MX19 Crimper Die (Part No. HD-50120-6)

NEST

STRIP LENGTH

PART NO.

TERMINAL

2.0-2.5

0.051-0.098

72910-11

Socket

2.0-2.5

0.051-0.098

72909-11

HOME

A-28 2013 Sportster Service: Appendix A Connector Repair

Content .. 30 31 32 33 ..