Harley Davidson Sportster Models 2009. Service Repair Manual - page 69

6.7

SPEEDOMETER AND TACHOMETER: XL DUAL
GAUGE MODELS

SPEEDOMETER REMOVAL

NOTE

The speedometer and tachometer have backlight bulbs that
cannot be replaced. If the bulb fails, replace the entire unit.

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

1.

Unplug main fuse. See 

6.38 MAIN FUSE

.

2.

Remove trip odometer reset boot from housing back plate.

3.

Remove screws holding speedometer housing back plate.

4.

Open latches on each side of speedometer connector [39]
and separate connector halves.

5.

Push out the speedometer and front gasket.

6.

Inspect front and back gaskets, speedometer connector
[39] and wiring, trip odometer reset switch and wiring, and
trip reset boot. Repair or replace as required.

SPEEDOMETER INSTALLATION

1.

If replacing the trip odometer reset switch, see

6.7 SPEEDOMETER AND TACHOMETER: XL DUAL

GAUGE MODELS, Trip Odometer Reset Switch
Replacement

.

2.

See 

Figure 6-18

. Install front gasket (4) on speedometer

(1).

3.

Thread wiring through back gasket (8) and install matching
tabs of gasket to locating keys in instrument
housing/bracket (5).

NOTE

If necessary, lubricate rubber gaskets with alcohol or glass
cleaner.

4.

Orient face upright and press speedometer (1) into
instrument housing/bracket (5). Wiring must pass between
locating keys and back gasket and through cutout in
speedometer back.

5.

Mate speedometer connector halves [39].

6.

Push trip odometer reset switch (2) through housing back
plate (6) and thread on the trip reset boot (3).

7.

Align back plate (6) with vent hole (15) at bottom with reset
switch (2) in rectangular boss in back of speedometer (1)
and thread in and tighten screws (14).

8.

Plug in main fuse. See 

6.38 MAIN FUSE

.

HOME

6-14  2009 Sportster Service: Electrical

7

5

14

15

6

1

13

10

11

9

8

12

2

3

4

sm01671

9.

1.

Tachometer

Speedometer

2.

10.

Trip odometer reset switch

Instrument harness connector [20A]

11.

3.

Indicator lamp module

Reset switch boot

4.

12.

Front gasket (2)

Speedometer connector [38B]

13.

5.

Tachometer connector [108B]

Instrument housing/bracket

6.

14.

Speedometer back plate

Screw (4)

15.

7.

Vent hole

Tachometer back plate

8.

Back gasket (2)

Figure 6-18. Speedometer and Tachometer: Dual Gauge Models

TRIP ODOMETER RESET SWITCH
REPLACEMENT

TOOL NAME

PART NUMBER

CRIMPING TOOL

HD-45929

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

1.

Unplug main fuse. See 

6.38 MAIN FUSE

.

2.

Remove trip odometer reset boot from back plate.

3.

Remove screws holding speedometer housing backplate.

4.

See 

Figure 6-19

. Open latches on each side of speedo-

meter connector [39] (1) and separate connector halves.

5.

Follow instructions to push the trip reset socket terminals
out the front of the speedometer socket connector half
[39B]. See 

A.16 PACKARD MICRO-64 CONNECTORS

.

6.

Cut off the socket terminals and pull the faulty switch out
of the connector.

7.

Push the wires of a replacement switch through the
speedometer connector (sockets 8, 11) and crimp new
socket terminals using CRIMPING TOOL (Part No. HD-
45929), on replacement switch wiring.

8.

Draw the terminal back into the connector until the terminal
seats.

9.

Position reset switch in squared boss on back of speedo-
meter housing.

HOME

2009 Sportster Service: Electrical  6-15

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

1.

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

2.

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

1.

Hold the housings to match wire color to wire color.

2.

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

3.

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.

2

3

1

4

sm00002

1.

Attachment clip

2.

Release button

3.

Socket housing

4.

Pin housing

Figure A-1. AMP Multilock Connector

Removing Terminals from Housing

1.

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.

2.

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

3.

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.

4.

Press the tang in the housing to release the terminal.

a.

Socket: Lift the socket tang (8) up.

b.

Pin: Press the pin tang (7) down.

NOTE

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

5.

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

HOME

2009 Sportster Service: Appendix A Connector Repair  A-1

5

2

7

1

3

6

1

2

4

8

sm00013

1.

Latch

2.

Secondary lock open

3.

Pin housing

4.

Socket housing

5.

Pin terminal

6.

Socket terminal

7.

Tang (pin)

8.

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.

1.

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.

2.

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

3.

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

– AMP

1

2

3

– AMP

1

2

3

4

5

6

5

6

7

8

9

10

4

3

2

1

1

2

3

sm00005

1.

3-place housing

2.

6-place housing

3.

10-place housing

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

Secondary Locks (Socket Housings Shown)

Preparing Wire Leads for Crimping

1.

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

HOME

A-2  2009 Sportster Service: Appendix A Connector Repair

2.

See 

Figure A-2

 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).

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

20

Middle

16

Rear

18

2

3

1

sm00004

1.

Insulation crimp tail

2.

Wire crimp tail

3.

Locking bar groove

Figure A-4. AMP Multilock Connector: Pin Terminal

2

3

1

sm00001

1.

Insulation crimp tail

2.

Wire crimp tail

3.

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.

1.

See 

Figure A-6

. Squeeze the handles to cycle the AMP

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

2.

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

NOTE

See 

Figure A-2

 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.

3.

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.

4.

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.

5.

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

6.

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

7.

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

8.

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

HOME

2009 Sportster Service: Appendix A Connector Repair  A-3

4

6

7

3

1

2

5

8

sm00007

1.

Open position

2.

Locking bar flange

3.

Insert contact

4.

Release locking bar

5.

Insert lead

6.

Squeeze

7.

Raise locking bar

8.

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.

1

2

sm00008

1.

Insulation crimp

2.

Wire core crimp

Figure A-7. AMP Multilock Connector: Terminal Crimp

HOME

A-4  2009 Sportster 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

1.

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

2.

See 

Figure A-8

 or 

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.

3.

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

4.

If necessary, crimp new terminals on wires.

Assembly

1.

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

2.

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 Sportster 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.

1.

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.

2.

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

3.

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.

1.

Gently push tang on socket housing inward toward
chamber. With the open side of the terminal facing the
tang, push terminal into chamber at wire end of socket
housing.

2.

Gently tug on wire to verify that terminal is locked and will
not back out of chamber. If necessary, use fingernail to
push tang into engagement with terminal.

3.

Install colored terminal lock onto mating end of socket
housing.

4.

If present, seat wires in separate channels of wire lock
and then push channels inside chambers at wire end of
socket housing. Fully installed, slot on each side of wire
lock engages ear on socket housing.

sm00014

Figure A-10. Delphi Connector: Socket Housing Latch

HOME

A-6  2009 Sportster Service: Appendix A Connector Repair

2

3

1

sm00015

1.

Remove wire lock

2.

Remove terminal lock

3.

Pry tang outward

Figure A-11. Delphi Connector: Removing Socket

Terminals

HOME

2009 Sportster Service: Appendix A Connector Repair  A-7

A.4

DELPHI MAIN FUSE HOUSING

DELPHI MAIN FUSE HOUSING REPAIR

General

A Delphi Main fuse connector completes the circuit through
the main fuse.

Removing Main Fuse

1.

See 

Figure A-12

. Depress latches on main fuse cover (1)

and then slide cover off of connector (2).

2.

Holding the connector (fuse holder), pull the main fuse out
of the connector.

Installing Main Fuse

1.

Insert the blade terminals of the main fuse into the sockets
of the connector and press the main fuse into the con-
nector.

2.

Slide the cover over the fuse until the cover clicks into
place.

NOTE

If removed from an OE attachment such as a grooved fuse
block cover, engage cover and slide into place.

Removing Socket Terminals

1.

Disconnect battery. See 

1.17 BATTERY MAINTENANCE

.

2.

See 

Figure A-13

. Disengage slots (1) on secondary lock

(2) from tabs (3) and remove secondary lock.

3.

Insert flat blade of pick or small screwdriver into opening
(4) until it stops.

4.

Tug on cable to pull socket from connector housing. Pivot
the pick toward the terminal body to release the latch if
necessary.

5.

Repeat to remove remaining socket terminal.

Installing Socket Terminals

1.

See 

Figure A-14

. Carefully bend tang outward away from

the terminal body.

2.

Properly orient terminal to the cavity in the housing and
push terminal into connector housing until it clicks in place.
Verify that socket will not back out of chamber.

3.

Push rubber seal into connector housing.

4.

Repeat to install remaining socket terminal.

5.

Install secondary lock onto connector housing. be sure
slots engage tabs on sides of connector housing.

6.

Connect battery cables. See 

1.17 BATTERY MAINTEN-

ANCE

.

1

2

sm00032

1.

Main fuse cover

2.

Delphi main fuse housing

Figure A-12. Delphi Connector Housing: Main Fuse

HOME

A-8  2009 Sportster Service: Appendix A Connector Repair

3

4

1

2

sm00033

1.

Secondary lock slot

2.

Secondary lock

3.

Tab

4.

Insert flat blade into opening

Figure A-13. Delphi Main Fuse Housing: Remove Socket

Terminals

sm00034

Figure A-14. Delphi Main Fuse Housing: Bend Tang

HOME

2009 Sportster Service: Appendix A Connector Repair  A-9

A.5

DEUTSCH ELECTRICAL CONNECTORS

DEUTSCH CONNECTOR REPAIR

TOOL NAME

PART NUMBER

DEUTSCH CONNECTOR SERVICE
KIT

HD-41475

FLAT BLADE L-HOOK

HD-41475-100

General

Deutsch 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 con-
nectors, including those associated with right side accessories,
are black.

NOTE

A DEUTSCH CONNECTOR SERVICE 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-15

. To separate the connector halves, depress

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

1.

Align the connectors to match the wire lead colors.

a.

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.

b.

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

2.

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.

3.

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

4.

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

2

3

1

1

sm00017

1.

External latch

2.

Socket housing

3.

Pin housing

Figure A-15. Deutsch Connector

Removing Socket Terminals

1.

See 

Figure A-16

. 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.

2.

See 

Figure A-19

. Use a pick or small screwdriver to

depress 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

1.

Match wire lead color to connector cavity.

2.

See 

Figure A-18

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

housing (2), if removed.

3.

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.

4.

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

HOME

A-10  2009 Sportster Service: 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.

5.

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

6.

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-17

. 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-16. Deutsch Connector: Remove Secondary

Locking Wedge

2

1

sm00018

1.

Arrow on socket locking wedge

2.

Arrow on pin locking wedge

Figure A-17. Deutsch Connector: 3-Place Locking Wedges

HOME

2009 Sportster Service: Appendix A Connector Repair  A-11

DEUTSCH

6

1

2

3

4

5

sm00010

1.

Wire seal

2.

Socket housing

3.

Wire lead

4.

Internal seal

5.

Secondary locking wedge

6.

Seal plug

Figure A-18. Deutsch Connector: 2, 3, 4 and 12-Place

Socket Housings

Removing Pin Terminals

1.

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.

2.

Gently depress 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, please note that the 8-place and 12-place gray
and black connectors are not interchangeable. Since loc-

ation of the alignment tabs differ between the black and
gray connectors, 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, and vice versa. The
socket and pin housings of all other connectors are inter-
changeable, that is, the 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-19. Deutsch Connector: Depress Terminal Latch

and Back Out Pin

Installing Pin Terminals

1.

See 

Figure A-20

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

(2).

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.

3.

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-17

. 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.

HOME

A-12  2009 Sportster Service: Appendix A Connector Repair

DEUTSCH

1

2

3

4

sm00020

1.

Wire seal

2.

Pin housing

3.

Pin terminal

4.

Locking wedge

Figure A-20. Deutsch 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-2

.

Table A-2. Deutsch Connector: Terminal Crimping Instructions

CRIMPING INSTRUCTIONS

TYPE

A.6 DEUTSCH STANDARD TERMINAL REPAIR

Standard (with crimp tails)

A.7 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR

Mini Terminal (solid barrel)

A.8 DEUTSCH MINI TERMINAL REPAIR

Mini Terminal (with crimp tails)

HOME

2009 Sportster Service: Appendix A Connector Repair  A-13

A.6

DEUTSCH STANDARD TERMINAL REPAIR

DEUTSCH STANDARD TERMINAL CRIMPS

TOOL NAME

PART NUMBER

DEUTSCH TERMINAL CRIMP TOOL

HD-39965-A

Preparing Wire Leads for Crimping

1.

Use a shop gauge to determine gauge of wire lead.

2.

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

Crimping Terminal to Lead

1.

See 

Figure A-21

. Squeeze the handles of the DEUTSCH

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

2.

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-3

.

3.

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.

4.

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.

5.

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

6.

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-3. Deutsch Standard Terminal Crimp: Wire Gauge

To Die

CRIMP TOOL DIE

WIRE GAUGE (AWG)

Front

20

Middle

16-18

2

5

4

6

1

3

sm00021

4.

1.

Insert stripped lead

Open jaws and raise locking bar

2.

5.

Insert terminal in locking bar

Squeeze crimper

6.

3.

Raise locking bar and remove terminal

Release locking bar to lock terminal in die

Figure A-21. Crimping a Deutsch Standard Terminal

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A-14  2009 Sportster Service: Appendix A Connector Repair