Buell 2003XB9S, Service Manual

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2003 Buell XB9S: Appendix B B-7
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NOTE
An ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD-
39965) is used to install Deutsch pin and socket terminals on
wires. If
new terminals must be installed, see Crimping
Instructions in this section.
3. Fit wire seal into back of pin housing. Grasp crimped pin
approximately 1.0 in. (25.4 mm) behind the contact bar-
rel. 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.
NOTES
●
While rectangular wedges do not require a special orien-
tation, the conical secondary locking wedge of the 3-pin
connector must be installed with the arrow pointing
toward the external latch. See
Figure B-9.
● 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.
ASSEMBLING/INSTALLING
1. Insert socket housing into pin housing until it snaps in
place. Two-, three-, four- and six-pin Deutsch connectors
have one external latch on the socket half of the connec-
tor. 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-pin
and 12-pin), 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
click (latch), press on one side of the connector until that
latch engages, then press on the opposite side to
engage the other latch.
NOTE
Deutsch connectors are color 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 accesso-
ries, are black.
If it should become necessary to replace a plug or receptacle,
please note that the 8-pin and 12-pin gray and black connec-
tors 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. See Figure B-11. Fit the attachment clip to the pin hous-
ing, if removed. Place large end of slot on attachment
clip over T-stud on frame. Push assembly forward to
engage small end of slot.
Figure B-10. Deutsch Connector Pick Tool
(Part No. HD-41475-100)
Figure B-11. Attachment Clip Installation
5893
5892
5891
Lock tab
Lock bar
Pin housing
Attachment clip
Attachment clip installed