Disconnect and connect
PART NUMBER | TOOL NAME |
HD-41475 | DEUTSCH TERMINAL REPAIR KIT |
HD-41475-100 | FLAT BLADE L-HOOK |
Notes: A DEUTSCH TERMINAL REPAIR KIT (Part No. HD-41475) contains a selection of seals and seal plugs, locking wedges, attachment clips and terminals.
Also included is a FLAT BLADE L-HOOK (Part No. HD-41475-100) used to remove locking wedges, compart-mented storage box and carrying case.
Disconnect
1. See Figure A-5. Press the latch(es) (1).
2. Pull the connector housings apart.
Connect
1. Align the connector housings.
2. Press the housings together until the latches snap into place.
![](https://motoinstruction.ru/img/harley/22/127944.jpg)
Figure A-5. Deutsch DT Sealed Connector: 1. External latch; 2. Socket housing; 3. Pin housing
Pin terminals: See Figure A-9. Use FLAT BLADE L-HOOK (Part No. HD-41475-100) or similar tool to pull the secondary locking wedge (4) from the pin housing.
2. See Figure A-7. Pry and hold the terminal latch away from the terminal.
3. Pull wire lead from housing.
Install terminal
1. See Figure A-8 or Figure A-9. Install rear wire seal (1) into housing (2), if removed.
2. Insert the terminal through the hole in wire seal and into the cavity. Terminal will snap into place.
3. Pull wire to confirm that terminal is properly seated.
Note. Install seal plugs (6) into unused chambers, if removed.
4. Socket Housing: See Figure A-8. Install internal seal (4) on lip of housing, if removed.
Notes: See Figure A-6. Three-place connectors: Align arrow (1) on conical secondary lock towards external latch.
If the secondary locking wedge does not install easily, check housing for unseated terminals.
5. Install secondary lock. Lock will snap into place.
![](https://motoinstruction.ru/img/harley/22/127945.jpg)
Figure A-6. Deutsch DT Sealed Connector: 3-Place Locking Wedges: 1. Arrow on socket locking wedge; 2. Arrow on pin locking wedge
![](https://motoinstruction.ru/img/harley/22/127946.jpg)
Figure A-7. Deutsch DT Sealed Connector: Press Terminal Latch and Pull Out Pin
![](https://motoinstruction.ru/img/harley/22/127947.jpg)
Figure A-8. Deutsch DT Sealed Connector: 2, 3, 4 and 12-Place Socket Housings: 1. Wire seal; 2. Socket housing; 3. Wire lead; 4. Internal seal; 5. Secondary locking wedge; 6. Seal plug
![](https://motoinstruction.ru/img/harley/22/127948.jpg)
Figure A-9. Deutsch DT Sealed Connector: 2, 3, 4 and 12-Place Pin Housings: 1. Wire seal; 2. Pin housing; 3. Pin terminal; 4. Locking wedge
Crimp terminal
PART NUMBER | TOOL NAME |
HD-39965-A | DEUTSCH TERMINAL CRIMP TOOL |
1. Determine wire lead gauge.
2. Remove 4.0 mm (0.15 in) of insulation from the wire lead.
3. See Figure A-10. Open the jaws of the DEUTSCH TERMINAL CRIMP TOOL (Part No. HD-39965-A). Push the locking bar (1) up.
4. Match the wire gauge to the crimp tool die. Refer to Table A-1.
Note: Rest the rounded side of the contact barrel in the nest (concave split level area) with the crimp tails facing up.
5. Insert (2) terminal through hole of the locking bar.
6. Release locking bar to lock terminal in die.
Note. If the crimp tails are slightly out of alignment, the crimp tool rotates the terminal to face the tails up. When positioned, the locking bar fits in the space between the contact band and the core crimp tails.
7. Insert stripped wire core between crimp tails until ends make contact with locking bar. Position wire so that the wide pair of crimp tails squeeze bare wire strands, while the narrow pair folds over the insulation material.
8. Squeeze handle of crimp tool until tightly closed. Tool automatically opens after the terminal is crimped.
9. Raise locking bar up to remove wire lead and terminal.
10. Inspect the wire core and insulation crimps. Distortion should be minimal.
Table A-1. Deutsch DT Sealed Terminal Crimp: Wire Gauge To Die
WIRE GAUGE (AWG) | CRIMP TOOL DIE |
20 | Front |
16-18 | Middle |
![](https://motoinstruction.ru/img/harley/22/127949.jpg)
Figure A-10. Crimping a Deutsch DT Sealed Terminal: 1. Open jaws and raise locking bar; 2. Insert terminal in locking bar; 3. Release locking bar to lock terminal in die; 4. Insert stripped lead; 5. Squeeze crimper; 6. Raise locking bar to remove terminal