Harley Davidson Touring 2004 Service Manual sm appb1

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DEUTSCH ELECTRICAL CONNECTORS B.1

GENERAL

Attachment clips are attached to the pin housings of some connectors. The clips are then attached to T-studs on the motorcycle frame. T-studs give positive location to electrical connectors and wire harnesses. Consistent location reduces electrical problems and improves serviceability.

To become familiar with the Deutsch connector, read the parts description below while referencing the 12-place connector illustrated in Figure B-3.

Soc

ket housing: alignment tabs and/or external latch, sec-

ondary locking wedge, internal seal, wire seal, seal pin.

NOTE

Seal pins or plugs are installed in the wire seals of unused chambers. If removed, seal pins must be replaced to maintain the integrity of the environmental seal.

Pin housing secondary locking wedge, wire seal, seal pin.

: alignment grooves and/or external latch cover,

REMOVING/DISASSEMBLING

1. Push the connector to disengage small end of slot on attachment clip fromT-stud. Lift connector off T-stud.

2. Depress the external latch(es) on the socket housing side and use a rocking motion to separate the pin and socket halves. Two-, three-, four- and six-place Deutsch connectors have one external latch, while eight- and twelve-place connectors have two, both of which must be pressed simultaneously to separate the connector halves.

4566

Figure B-2. Depress Terminal Latches/Back Out Pins

NOTE

With few exceptions, the socket housing can always be found on the accessory side, while the pin side of the connector is plumbed to the wiring harness.

REMOVING/INSTALLING SOCKETS

1. See Figure B-1. Remove the secondary locking wedge. Insert the blade of a small screwdriver between the socket housing and locking wedge inline with the groove (inline with the pin holes if the groove is absent). Turn the screwdriver 90 degrees to pop the wedge up.

2. Gently depress terminal latches inside socket housing and back out sockets through holes in rear wire seal. See Figure B-2.

NOTE

If new terminals must be installed, see CRIMPING

INSTRUCTIONS in this section.

Figure B-1. Remove Secondary Locking Wedge

3. Fit rear wire seal into back of socket housing, if removed. Grasp socket approximately 1 inch (25.4 mm) behind the contact barrel. Gently push sockets through holes in wire seal into their respective chambers. Feed socket into chamber until it “clicks” in place. Verify that socket will not back out of chamber; a slight tug on the wire will conﬁrm that it is properly locked in place.

4. Install internal seal on lip of socket housing, if removed. Insert tapered end of secondary locking wedge 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.

Appendix B B-1

HOME

Terminal

Latch Cover

Wire Seal

Alignment

Grooves

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Housing

Locking Wedge

(Pin Side)

Locking Wedge

(Socket Side)

Internal

Seal

Socket

Housing

Wire Seal

NOTE

For exploded views of 2-place, 3-place and 4-place Deutsch connectors, see Figure B-5.

Figure B-3. 12-Place Deutsch Connector (Exploded View)

NOTE 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 pointing toward the external latch. See Figure B-4.

NOTE 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.

REMOVING/INSTALLING PINS

Alignment

Tabs

Housing

Socket

Housing

Seal

External

Latch

Socket

Terminal

Arrow Points to

External Latch

1. Remove the secondary locking wedge. Use the hooked

end of a stiff piece of mechanics wire, a needle nose pliers or a suitable pick tool (HD-41475-100). See Figure

B-6.

B-2 Appendix B

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Figure B-4. 3-Place Locking Wedge Orientation

HOME

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2-Place Connector

3-Place Connector

Socket Side

1. Socket Terminal

2. Wire Seal

3. Socket Housing

4. External Latch

5. Internal Seal

6. Locking Wedge

DEUTSCH

Pin Side

7. Locking Wedge

8. Latch Cover

9. Pin Housing

10. Wire Seal

11. Pin Terminal

4-Place Connector

DEUTSCH

Figure B-5. 2-Place, 3-Place and 4-Place Deutsch Connectors

Appendix B B-3

HOME

Figure B-6. Deutsch Connector Pick Tool

(Part No. HD-41475-100)

2. Gently depress terminal latches inside pin housing and

back out pins through holes in wire seal.

NOTE If new terminals must be installed, see CRIMPING

INSTRUCTIONS on this page.

3. Fit wire seal into back of pin housing. Grasp crimped pin

approximately 1 inch (25.4 mm) behind the contact barrel. Gently push pins through holes in wire seal into their respective numbered locations. Feed pin into chamber until it “clicks” in place. Verify that pin will not back out of chamber; a slight tug on the wire will conﬁrm that it is properly locked in place.

4. Insert tapered end of secondary locking wedge into pin

housing and press down until it snaps in place. The wedge ﬁts in the center groove within the pin housing and holds the terminal latches tightly closed.

click (latch), press on one side of the connector until that latch engages, then press on the opposite side to engage the other latch.

NOTES

Deutsch connectors are colored coded for location pur-

●

poses. Those connectors associated with accessories, such as the front and rear are

gray

. All other connectors, including those associ-

ated with right side accessories, are black.

If it should become necessary to replace a plug or

●

receptacle, please note that the 8-place and 12-place gray and black connectors are not interchangeable. Since location of the alignment tabs differ between the black and gray connectors, plugs or receptacles must be replaced by those of the same color. If replacing both the socket and pin halves, then the black may be substituted for the gray, and vice versa. The socket and pin halves of all other connectors are interchangeable, 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.

2. Fit the attachment clip to the pin housing, if removed. Place large end of slot on attachment clip over T-stud on frame. Push assembly forward to engage small end of slot.

left

turn signals,

left

side

NOTE

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 pointing toward the external latch. See Figure B-4.

NOTE

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 terminals are not properly installed by not entering its fully installed position.

ASSEMBLING/INSTALLING

1. Insert socket housing into pin housing until it snaps in place. 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 those connectors with two external latches (8-place and 12-place), a different system is used to prevent improper assembly. Align the tabs on the socket housing with the grooves on the pin housing. Push the connector halves together until the latches “click.” If latches do not

CRIMPING INSTRUCTIONS

Use the Deutsch Terminal Crimp Tool (HD-39965) to install standard size terminals with crimp tails, as described under

STANDARD TERMINALS below. To install the mini-Deutsch

terminals with crimp tails, see MINI TERMINALS, which follows. To install those terminals without crimp tails, both standard and mini-Deutsch, use the Deutsch Solid Barrel Contact Crimp Tool (HD-42879) as described under SOLID BARREL

CONTACTS.

NOTE

A Deutsch Connector Service Kit (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 pick tool (HD-41475-100) used for the removal of all types of locking wedges.

STANDARD TERMINALS

1. Obtain the DEUTSCH TERMINAL CRIMP TOOL (HD-

39965).

2. Squeeze the handles to cycle the crimp tool to the fully open position. See Figure B-7.

B-4 Appendix B

HOME

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2.1.

Gauge

Wire

20 Front

16-18 Middle

Locking

Bar

1. Insert contact through hole of locking bar so that barrel rests on nest of crimp tool.

Nest of

Crimp Tool

2. Insert stripped lead until it contacts locking bar.

3. Close and squeeze crimp tool. 4. Raise locking bar and remove contact.

Insulation crimp Core crimp

5. Inspect quality of core and insulation crimps.

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Figure B-7. Deutsch Crimping Procedure

Appendix B B-5

HOME

3. Raise the locking bar by pushing up on bottom ﬂange. With the crimp tails facing upward, insert contact (socket/pin) through hole of locking bar, so that the rounded side of the contact barrel rests on the nest (concave split level area) of the crimp tool. Use the middle hole in the locking bar for 16-18 gauge wire, the front hole for 20 gauge wire.

4. Release locking bar to lock position of contact. If the crimp tails are slightly out of vertical alignment, the crimp tool automatically rotates the contact so that the tails face straight upward. When correctly positioned, the locking bar ﬁts snugly in the space between the contact band and the core crimp tails.

5. Strip lead removing 5/32 inch (4.0 mm) of insulation. Insert wires 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 insulation material.

6. Squeeze handle of crimp tool until tightly closed. Tool automatically opens when the crimping sequence is complete. Raise up locking bar and remove contact.

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

MINI TERMINALS

1. Obtain the PACKARD TERMINAL CRIMP TOOL (HD38125-7).

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

3. Compress handles until ratchet automatically opens.

NOTE

Always perform core crimp before insulation crimp.

4. Position the core cr sure the core crimp tails are facing the forming jaws.

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

6. Insert stripped wire between crimp tails. Verify that wire is positioned so that short pair of crimp tails squeeze bare wire strands, while long pair is positioned over the insulation material.

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

8. Position the insulation cr tool. Be sure the insulation crimp tails are facing the forming jaws.

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

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

imp on nest E of the crimping tool. Be

imp on nest C of the crimping

SOLID BARREL CONTACTS

For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG

1. Obtain the DEUTSCH SOLID BARREL CONTACT CRIMP TOOL (HD-42879).

2. Squeeze the handles to cycle the crimp tool to the fully open position.

3. Remove locking pin from selector knob. See Figure B-8.

4. Raise selector knob and rotate until selected wire size stamped on wheel is aligned with “SEL. NO.” arrow. See upper frame of Figure B-9.

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

6. Turn tool over and drop contact into indentor cover hole with the wire end out.

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

8. Slowly squeeze handles of crimp tool until contact is centered between indentor points. See middle frame of

Figure B-9.

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

10. Insert bare wire strands into contact barrel. See lower frame of Figure B-9.

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

12. Remove crimped contact from indentor.

13. Inspect the quality of the crimp. Verify that all wire strands are in crimp barrel.

Adjusting

Screw

u m l

H s i

i d e

n i f

s a '

' S S

)

4 (

1 2 .

1 R F

Locknut

Figure B-8. Deutsch Solid Barrel Contact Crimp Tool

(Part No. HD-42879)

Locking

Selector

Knob

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B-6 Appendix B

HOME

Rotate selector knob to align wire size on wheel with arrow stamped in tool.

Selector

Knob

)

(

f1534x8x

Turn adjusting screw as described in text. When contact is ﬂush with bottom of depression in indentor cover, squeeze handles to center contact between indentor points.

Indentor

Cover

Contact

NOTE

Tool must be readjusted when changing contact size/type.

14. Install pin to lock position of selector knob.

HEMET RYAN AIRPORT, P.O. BOX 878

HEMET, CA. 92343-0161 (714) 929-1200

HDT - 48 - 00

JDG360-1

Indentor

Points

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Insert bare wire strands into contact barrel. Squeeze handle of crimp tool until tightly closed.

HEMET RYAN AIRPORT, P.O. BOX 878

HEMET, CA. 92343-0161 (714) 929-1200

INDUSTRIAL PRODUCTS DIVISION

HDT - 48 - 00

JDG360-1

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Figure B-9. Deutsch Solid Barrel Contact

Crimping Procedure

Appendix B B-7

HOME

PLACE

CABLE CONNECTOR

General

Use the following instructions to service the voltage regulator cable connector.

Removal

1. Depress external latch and separate pin and socket halves of connector.

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

3. Obtain terminal pick tool (Deutsch® 114008) like that shown in A of Figure B-10.

CAUTION

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

4. Install terminal pick tool onto voltage regulator cable so that the tapered end is in the wire end of the housing. See B of Figure B-10.

5. Push tool into wire end of housing until it bottoms. Gently tug on housing to pull from terminal. See C of Figure

B-10.

6. Remove tool from voltage regulator cable.

7786

7787

Installation

1. 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.

2. Fit rear wire seal into back of housing.

3. Mate pin and socket halves of connector.

7788

Figure B-10. Remove Socket/Pin Housing

B-8 Appendix B

HOME

AMP MULTILOCK ELECTRICAL CONNECTORS B.2

REMOVING SOCKET/PIN TERMINALS

1. Remove connector from the retaining device, either attachment or rosebud clip.

2. Depress the button on the socket terminal side of the connector (plug) and pull apart the pin and socket halves. See Figure B-11.

3. Bend back the latch slightly and free one side of secondary lock, then repeat the step to release the other side. Rotate the secondary lock outward on hinge to access terminals in chambers of connector housing.

4. Looking in the terminal side of the connector (opposite the secondary lock), take note of the cavity next to each terminal.

5. See Figure B-12. With the ﬂat edge against the terminal, insert the pick (Snap-On TT600-3) into the cavity until it stops. Pivot the end of the pick away from the terminal and gently tug on wire to pull terminal from chamber. Do not tug on the wire until the tang is released or the terminal will be difﬁcult to remove. A “click” is heard if the tang

Secondary Lock

Open

Pin Terminal

is engaged but then inadvertently released. Repeat the step without releasing the tang.

NOTE

An Electrical Terminal Crimp Tool (Part No. HD-41609) is used to install Amp Multilock pin and socket terminals on wires. If new terminals must be installed, see CRIMPING

INSTRUCTIONS in this section.

INSTALLING SOCKET/PIN TERMINALS

NOTE

For wire location purposes, numbers are stamped into the secondary locks of both the socket and pin housings. See

Figure B-14.

1. From the secondary lock side of the connector, insert the terminal into its respective numbered chamber until it snaps in place. For proper ﬁt, the slot in the terminal must face the tang in the chamber.

NOTE

For exploded views of 3-place and 6-place Amp Multilock connectors, see Figure B-15.

Latch

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Pin Housing

Figure B-11. 10-Place Amp Multilock Connector (Exploded View)

Socket Housing

Latch

Button

Secondary Lock

Open

Secondary Lock

Open

Latch

Socket Terminal

Appendix B B-9

HOME

Secondary Lock

Open

f1289x2x

Pin Terminal

Socket Terminal

Secondary Lock

Open

Socket Housing

Pick Tool

Pin Housing

1. Open Secondary Lock.

2. Insert Pick into Cavity on Mating End of Connector.

3. Pivot End of Pick to Release Tang.

4. Gently Tug on Wire to Remove Terminal from Housing.

Figure B-12. Release Tang and Back Out Terminals

NOTE The tang in the chamber engages the slot to lock the terminal in position. On the pin side of the connector, tangs are positioned at the bottom of each chamber, 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 chamber, so the socket terminal slot (on the same side as the crimp tails) must face upward. Up and down can be determined by the position of the release button (used to separate the pin and socket halves), the button always being the top of the connector. See Figure B-13.

2. Gently tug on wire end to verify that the terminal is

locked in place and will not back out of chamber.

Pin Housing

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Figure B-13. Tang Location (Cross Sectional View)

Tang

Button

Socket Housing

B-10 Appendix B

HOME

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– AMP

123

3-Place Connector 6-Place Connector 10-Place Connector

Figure B-14. Numbers Stamped on Secondary Locks for Wire Color Locations (Socket Housings Shown)

3-Place Connector

Secondary Locks Open

– AMP

123456

56 78 910

43 21

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6-Place Connector

Socket Side

12. Socket Terminal

13. Secondary Lock (Open)

14. Latch

15. Socket Housing

16. Button

Pin Side

17. Pin housing

18. Latch

19. Secondary Lock (Open)

20. Pin Terminal

f1288x2x

Figure B-15. 3-Place and 6-Place Amp Multilock Connectors

Appendix B B-11

HOME

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PIN TERMINAL SOCKET TERMINAL

Insulation Crimp Tail

Core

Crimp Tail

Locking Bar

Groove

Tang Slot

Locking Bar

Groove

Tang Slot

Crimp Tail

2.1.

Locking

Bar

Core

Insulation Crimp Tail

f1290a2x

1. Raise locking bar and seat contact on nest of crimp tool. Release locking bar.

3. Close and squeeze crimp tool. 4. Raise locking bar and remove contact.

Figure B-16. Amp Multilock Crimping Procedure

2. Insert stripped lead until it contacts locking bar.

Gauge

Wire

20 Front

16 Middle

18 Rear

Nest of

Crimp Tool

B-12 Appendix B

HOME

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

4. Insert the socket housing (plug) into the pin housing (receptacle) until it snaps in place.

5. Install connector on retaining device, either attachment or rosebud clip.

CRIMPING INSTRUCTIONS

1. Squeeze the handles to cycle the crimp tool (Part No. HD-41609) to the fully open position.

2. Raise locking bar by pushing up on bottom ﬂange. With the crimp tails facing upward, insert contact (socket/pin) through locking bar, so that the closed side of the contact rests on the nest (concave split level area) of the crimp tool). Use the front nest for 20 gauge wire, the middle for 16 gauge and the rear for 18 gauge. See Fig-

ure B-16.

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.

4. Strip lead removing 5/32 inch (4.0 mm) of insulation. Insert wires 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 insulation material.

5. Squeeze handle of crimp tool until tightly closed. Tool automatically opens when the crimping sequence is complete. Raise up locking bar and remove contact.

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

Appendix B B-13

HOME

PACKARD ELECTRICAL CONNECTORS B.3

150 METRI-PACK SERIES

General

Use these instructions to service the following connectors:

●

MAP Sensor [80B] Ignition Coil [83B/130B]

●

IAC Actuator [87B]

●

TP Sensor [88B] ET Sensor [90B]

●

IAT Sensor [89B]

Disassembly

1. Remove the connector from the retaining device, if present.

2. Bend back the external latch(es) slightly and separate the pin and socket halves of the connector.

3. To free a pull-to-seat terminal from the connector housing, ﬁrst look into the mating end of the connector to ﬁnd the locking tang. See A in Figure B-18. The tangs are always positioned in the middle of the chamber and are on the same side as the external latch. On those connectors with locking ears, the tang is on the side opposite the ear. See Figure B-19.

4. At a slight angle, gently insert the point of a one inch safety pin down the middle of the chamber about 1/8 inch (3.2 mm), and pivot the end of the pin toward the terminal body. When a click is heard, remove the pin and repeat the procedure. See B in Figure B-18. The click is the sound of the tang returning to the locked position as it slips from the point of the pin. Pick at the tang in this manner until the clicking stops and the pin seems to slide in at a slightly greater depth than it had previously. This is an indication that the tang has been depressed.

2-Place

IAT Sensor Connector [89B]

2-Place

ET Sensor Connector [90B]

3-Place

ABC

TP Sensor Connector [88B]

4-Place

ABCD

NOTE

On those terminals that have been extracted on a previous occasion, no clicking sound may be heard when the pin is pivoted to depress the tang, but proceed as if the clicking is audible and then push on the wire end of the lead to check if the terminal is free.

NOTE

When picking multiple terminals, the end of the pin may become malleable. For best results, continue the procedure with a new safety pin.

B-14 Appendix B

IAC Connector [87B]

Figure B-17. Packard External Latch Type Connectors

(Socket Sides)

5. Remove the pin and push on the wire end of the lead to extract the terminal from the mating end of the connector. See C in Figure B-18. If necessary, pull back the conduit and remove the wire seal at the back of the connector to introduce some slack in the wires.

HOME

f1360x8x

Locate tang on latch side of chamber. Push on wire end of lead to remove terminal.

Pivot end of pin to depress tang.

Figure B-18. Depress Tang and Extract Terminal From Mating End of Connector

6. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

Assembly

NOTE

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

Raise tang and re-install terminal.

2. Gently pull on the lead at the wire end of the connector to draw the terminal back into the chamber. A click is heard when the terminal is properly seated.

3. Push on the lead to verify that the terminal is locked in place.

4. Push the pin and socket halves of the connector together until the latches “click.”

1. Using a thin ﬂat blade, like that on an X-Acto knife, carefully bend the tang outward away from the terminal body. See D in Figure B-18.

Figure B-19. Packard Pull-to-Seat Terminal Connector

With Locking Ear

280 METRI-PACK SERIES

General

Use these instructions to service the following:

Front/Rear Fuel Injectors [84B/85B]

●

System Fuse Block [64B]

●

Fuel Injectors

Disassembly

1. Depress the wireform and use a rocking motion to detach the electrical connector.

2. Pry rubber seal from wire end of connector and move seal down wires toward conduit.

Appendix B B-15

HOME

A. Insert safety pin at wire end of connector to depress tang.

B. Push on wire end of lead to remove terminal.

BC D

C. Raise tang with blade of X-Acto knife.

D. Pull on wire end of lead to draw terminal back into chamber.

f2012x9x

Figure B-20. Extract/Install Socket Terminal at Mating End of Connector

3. Hold the connector so that the wireform is facing down, and looking into the wire end of the connector, insert the point of a safety pin between the top of the terminal and the inside chamber wall.

4. Push safety pin completely into chamber while watching terminal on mating end of connector. When terminal is observed moving forward slightly, then tang is depressed. See A in Figure B-20. Remove safety pin.

NOTE

Repeat steps 3 and 4 as necessary until the desired result is achieved.

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

the mating end of the connector. See B in Figure B-20.

6. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

Assembly

NOTE

For wire color locations, see Section B.8 WIRING DIA-

GRAMS and then refer to Figure B-21.

1. Using a thin ﬂat blade, like that on an X-Acto knife, carefully bend the tang outward away from the terminal body. See C in Figure B-20.

2. Gently pull on the lead at the wire end of the connector to draw the terminal back into the chamber. Be sure that the tang faces opposite the wireform as it enters the chamber. A “click” is heard when the terminal is properly seated. See D in Figure B-20.

3. Push on lead to verify that terminal is locked in place.

4. Fit rubber wire seal back into wire end of connector.

5. Push the pin and socket halves of the connector together until the latch “clicks.” The groove in the socket housing must be aligned with the tab in the pin housing.

Figure B-21. Fuel Injector Connector [84B/85B]

B-16 Appendix B

HOME

1WARNING1WARNING

Lip of

Locking Wedge

f2205x8x

1. Headlamp

2. Ignition

3. Lighting

4. Instruments

5. Brakes/Cruise

6. Radio Memory

7. Radio Power

8. Accessory

9. Battery

10. Brake Light Relay

11. P&A

f2204x8x

System Fuse Block

Disassembly

1. Remove system fuses and relay(s) from fuse block. See Section 8.3 SYSTEM FUSES, SYSTEM FUSES/

RELAYS, REMOVAL.

2. Remove secondary locks as follows: a. Insert end of small ﬂat blade screwdriver under lip of

locking wedge and gently pry up secondary lock.

NOTE

For best results, start with locking wedge on outboard side of secondary lock. See Figure B-22.

3. Remove socket terminals as follows: a. Looking into chamber at top of fuse block, note the

tang next to each socket terminal.

b. Using a thin ﬂat blade, like that on an X-Acto knife,

gently push tang away from terminal, and then tug on wire to back terminal out wire end of chamber.

4. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

Assembly

1. Install socket terminals as follows:

NOTE

See Section B.8 WIRING DIAGRAMS, MAIN HARNESS, for wire colors and locations.

a. 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.

b. Gently tug on the wire to verify that the terminal is

locked in place and will not back out of the chamber.

2. Install secondary locks as follows: a. 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. See Figure B-22.

3. Install system fuses and relay(s) in fuse block. See Section 8.3 SYSTEM FUSES, SYSTEM FUSES/RELAYS,

INSTALLATION.

480 METRI-PACK SERIES

General

Use the following instructions to service the B+ connector.

Figure B-22. Remove Secondary Locks From Fuse Block

Figure B-23. Fuse Block (FLTR, FLHTC/U)

Disassembly

1. Remove seat. See Section 2.24 SEAT, REMOVAL.

Always disconnect the negative battery cable ﬁrst. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion, which could result in death or serious injury.

2. Unthread bolt and remove battery negative cable (black) from battery negative (-) terminal.

Appendix B B-17

+ 37 hidden pages