Buell 2004 XB9S, Service Manual

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2004 Buell Lightning: Appendix B B-11
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PULL-TO-SEAT TERMINALS
Removing External Latch Type
To remove a pull-to-seat terminal from connectors with exter-
nal latches, proceed as follows:
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 hous-
ing, first look into the mating end of the connector to find
the locking tang. See A in
Figure B-14. The tangs are
always positioned in the middle of the chamber and are
on the same side as the external latch. On those connec-
tors with locking ears, the tang is on the side opposite
the ear.
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) 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-14. 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.
NOTES
● On those terminals that have been extracted on a previ-
ous 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.
● When picking multiple terminals, the end of the pin may
become malleable. For best results, continue the proce-
dure with a new safety pin.
5. Remove the pin and push on the wire end of the lead to
extract the terminal from the mating end of the connec-
tor. See C in
Figure B-14. If necessary, pull back the con-
duit and remove the wire seal at the back of the
connector to introduce some slack in the wires.
NOTE
A series of Packard Electrical Terminal Crimp Tools are avail-
able to install Packard pin and socket terminals on wires. If
new terminals must be installed, see Crimping Instructions.
Installing External Latch Type
NOTE
For wire location purposes, alpha characters are stamped
into the socket housings.
1. To install a terminal back into the chamber of the connec-
tor housing, use a thin flat blade, like that on an X-Acto
knife, and carefully bend the tang outward away from the
terminal body. See D in
Figure B-14.
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.”