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Harley Davidson Sportster Models 2009. Service Repair Manual - page 84

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Insulation crimp

Wire core crimp

Figure A-7. AMP Multilock Connector: Terminal Crimp

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2009 Sportster Diagnostics: Appendix A Connector Repair A-5

A.2

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-8

. 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.9 150 METRI-PACK CON-

NECTORS

to remove/install terminals in this connector.

See

Figure A-9

. 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.

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Figure A-8. Delphi Connector: Socket Housing Latch

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A-6 2009 Sportster Diagnostics: Appendix A Connector Repair

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Remove wire lock

Remove terminal lock

Pry tang outward

Figure A-9. Delphi Connector: Removing Socket Terminals

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2009 Sportster Diagnostics: Appendix A Connector Repair A-7

A.3

DEUTSCH 1-PLACE ELECTRICAL CONNECTORS

DEUTSCH 1-PLACE CONNECTOR REPAIR

Separating Pin and Socket Housings

Depress external latch and separate the pin and socket hous-
ings of the Deutsch one place connector found on voltage
regulators.

Mating Pin and Socket Housings

Orient the housings so the latch faces the catch and push the
housings together until it clicks.

Removing Socket Terminals

NOTE

Rough handling or careless storage can result in tool damage.
Exercise care to avoid cracking or breaking the thin plastic
construction.

Pull rear wire seal from back of housing and slide down
voltage regulator cable to move out of the way.

See

Figure A-10

. Using terminal pick tool (Deutsch®

114008) (1), install tool onto voltage regulator cable so
that the tapered end is in the wire end of the housing (2).

Push tool into wire end of housing until it bottoms. Gently
tug on housing to pull from terminal (3).

Remove tool from voltage regulator cable.

Installing Socket Terminals

Insert terminal into wire end of housing until it "clicks" in
place. Verify that terminal will not back out of housing. A
slight tug on the voltage regulator cable will confirm that
it is properly locked in place.

Fit rear wire seal into back of housing.

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Deutsch terminal pick tool (114008)

Tool installed in housing

Terminal removed from housing

Figure A-10. Deutsch 1-Place Connector: Remove

Socket/Pin Housing

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A-8 2009 Sportster Diagnostics: Appendix A Connector Repair

A.4

DEUSCH 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-10

. 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

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.

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External latch

Socket housing

Pin housing

Figure A-11. Deutsch Connector

Removing Socket Terminals

See

Figure A-12

. 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-15

. 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

Match wire lead color to connector cavity.

See

Figure A-14

. 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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2009 Sportster Diagnostics: Appendix A Connector Repair A-9

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-13

. 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-12. Deutsch Connector: Remove Secondary

Locking Wedge

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Arrow on socket locking wedge

Arrow on pin locking wedge

Figure A-13. Deutsch Connector: 3-Place Locking Wedges

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A-10 2009 Sportster Diagnostics: Appendix A Connector Repair

DEUTSCH

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Wire seal

Socket housing

Wire lead

Internal seal

Secondary locking wedge

Seal plug

Figure A-14. Deutsch 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 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-15. Deutsch Connector: Depress Terminal Latch

and Back Out Pin

Installing Pin Terminals

See

Figure A-16

. 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-13

. 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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2009 Sportster Diagnostics: Appendix A Connector Repair A-11

DEUTSCH

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Wire seal

Pin housing

Pin terminal

Locking wedge

Figure A-16. 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.5 DEUTSCH STANDARD TERMINALS

Standard (with crimp tails)

A.7 DEUTSCH SOLID BARREL TERMINALS

Mini Terminal (solid barrel)

A.6 DEUTSCH MINI-TERMINAL CRIMPS

Mini Terminal (with crimp tails)

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A-12 2009 Sportster Diagnostics: Appendix A Connector Repair

A.5

DEUTSCH STANDARD TERMINALS

DEUTSCH STANDARD 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-17

. 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-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.

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-3. Deutsch Standard Terminal Crimp: Wire Gauge

To Die

CRIMP TOOL DIE

WIRE GAUGE (AWG)

Front

Middle

16-18

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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-17. Crimping a Deutsch Standard Terminal

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2009 Sportster Diagnostics: Appendix A Connector Repair A-13

A.6

DEUTSCH MINI-TERMINAL CRIMPS

DEUTSCH 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-18

. 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.

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E die

Crimper ratchet trigger

Figure A-18. Packard Terminal Crimper (HD-38125-7)

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A-14 2009 Sportster Diagnostics: Appendix A Connector Repair

A.7

DEUTSCH SOLID BARREL TERMINALS

DEUTSCH 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-19

. 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-20

. 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-19. Electrical Crimper Tool (HD-42879)

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2009 Sportster Diagnostics: Appendix A Connector Repair A-15

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-20. Deutsch Solid Barrel

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A-16 2009 Sportster Diagnostics: Appendix A Connector Repair

A.8

RELAY AND FUSE BLOCKS

FUSE BLOCK REPAIR

Removing Socket Terminals

See

Figure A-21

. To remove secondary locks, insert end

of small flat blade screwdriver (1) under lip of locking
wedge (2) and gently pry up secondary lock.

NOTE

For best results, start with locking wedge on outboard side of
secondary lock.

Looking into chamber at top of fuse block, note the tang
next to each socket terminal.

Using a thin flat blade, like that on a hobby knife, gently
push tang away from terminal, and then tug on wire to
back terminal out.

Installing Socket Terminals

Match the wire lead color to the fuse block terminal cavity.

NOTES

•

Refer to the main harness wiring diagram for wire lead
color codes.

•

See

Figure A-22

. The main fuse block terminal cavity is

identified as alpha (1) and numeric (2) coordinates. Refer
to the main harness wiring diagram for fuse block terminal
cavity coordinates.

With the open side of the socket terminal facing the tang,
push lead into chamber at the wire end of the fuse block.
A click is heard when the terminal is properly engaged.

Gently tug on the wire to verify that the terminal is locked
in place and will not back out of the chamber.

Install the secondary locks. With the locking wedges
positioned above the tangs in each chamber, slide flat
side of secondary lock into slot (between rows), and push
down until it bottoms.

Crimping Terminals

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

A correctly crimped terminal may require different crimping
dies found on separate crimpers.

NOTE

The wiring diagram indicates when one socket terminal is be
crimped to two wire leads.

sm00025

Pry up secondary lock

Lip of locking wedge

Figure A-21. Fuse Block: Remove Secondary Locks

sm00026

Alpha

Numeric

Figure A-22. Fuse Block: Coordinates (typical)

HOME

2009 Sportster Diagnostics: Appendix A Connector Repair A-17

A.9

150 METRI-PACK CONNECTORS

150 METRI-PACK CONNECTOR REPAIR

General

Metri-Pack connectors are embossed with the initials (P.E.D.).

There are two types of connectors in this series:

•

Pull-to-Seat

•

Push-to-Seat

Separating Pin and Socket Housings

Bend back the external latch slightly and separate the pin and
socket halves of the connector.

Mating Pin and Socket Housings

Align the wire colors and push the pin and socket halves of the
connector together.

Removing Socket Terminal

See

Figure A-23

for pull-to-seat connector or

Figure A-24

for push to seat connector. Remove wire lock (1) from wire
end of socket housing on push-to-seat type connectors.

NOTE

For best results, free one side of wire lock first and then release
the other side.

Find the locking tang in the mating end of the connector.

NOTE

The tangs are always positioned in the middle of the chamber
and are on the same side as the external latch.

Gently insert a safety pin into the chamber about 1/8 in.
(3.2 mm).

For pull-to-seat: Stay between the terminal and the
chamber wall and pivot the end of the pin toward the
terminal body.

For push-to-seat: There is a small opening for the
pin.

When a click is heard, remove the pin and repeat the
procedure.

NOTE

The click is the sound of the tang returning to the locked posi-
tion as it slips from the point of the pin.

Pick at the tang until the clicking stops and the pin seems
to slide in deeper than it had previously. This is an indica-
tion that the tang has been depressed.

NOTE

On those terminals that have been extracted on multiple
occasions, the click may not be heard, but pivot the pin as if
the click was heard at least 3 times.

Remove the pin.

For pull-to-seat: Push on the lead to extract the ter-
minal from the mating end of the connector.

For push-to-seat: Pull on the lead to draw the ter-
minal out the wire end.

Inserting Socket Terminal

NOTE

For wire location purposes, alpha characters are stamped into
the socket housings.

See

Figure A-23

for pull-to-seat connector or

Figure A-24

for push to seat connector. Using a thin flat blade, like that
on a hobby knife, carefully bend the tang outward away
from the terminal body.

Gently pull or push on the lead to install the terminal back
into the chamber. A click is heard when the terminal is
properly seated.

Gently pull or push on the lead to verify that the terminal
is locked in place.

For push-to-seat: See

Figure A-24

. 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.

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A-18 2009 Sportster Diagnostics: Appendix A Connector Repair

sm00027

Locate tang in chamber

Pivot pin to depress tang

Push to remove

Raise tang to install

Figure A-23. 150 Metri-Pack Connector: Pull-to-Seat

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Remove wire lock

Pivot pin to depress tang

Pull to remove

Raise tang to install

Figure A-24. 150 Metri-Pack Connector: Push-to-Seat

HOME

2009 Sportster Diagnostics: Appendix A Connector Repair A-19

A.10

280 METRI-PACK CONNECTORS

280 METRI-PACK CONNECTOR REPAIR

General

See

Figure A-25

. Called Packard connectors, Metri-Pack series

connectors are embossed with the initials (P.E.D.)

Separating Pin and Socket Housings

Depress the wireform and use a rocking motion to detach the
socket connector half.

Mating Pin and Socket Housings

Align the groove in the socket housing with the tab in the pin
housing. Push the pin and socket halves of the connector
together until the latch clicks.

Removing Socket Terminals

See

Figure A-26

. Pry rubber seal from wire end of con-

nector and move seal down wires (1) toward conduit. Hold
the connector so that the wireform is facing down.

Looking into the wire end of the connector, insert the point
of a safety pin (2) between the top of the terminal and the
inside chamber wall.

Push safety pin completely into chamber while watching
terminal on mating end of connector. When terminal is
observed moving forward slightly, tang is depressed.
Remove safety pin.

NOTE

Repeat as necessary until the terminal can be pushed out of
the connector.

Push on wire end of the lead to extract the terminal from
the mating end of the connector.

If necessary, crimp new terminals on wires. See

A.14 METRI-PACK TERMINALS, Metri-Pack Terminal
Crimps

Installing Socket Terminals

NOTE

Terminal cavities are lettered on the socket housing. To match
the wire lead colors to the terminal cavity, refer to the wiring
diagram.

See

Figure A-26

. Using a thin flat blade, like a hobby knife

(4), carefully bend the tang outward away from the terminal
body.