Otis Singleton
Taking apart Harley electrical connectors can be a tricky task. While some connectors are small enough to pull through the bars, others may require more intricate methods. One popular method is to cut and extend the wires, although this is not recommended for those without the necessary skills. Depinning and repinning cables is another way to take apart Harley electrical connectors, although this can be time-consuming and challenging. It is important to take pictures or make diagrams of the connectors before taking them apart to ensure they are properly reassembled.
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What You'll Learn
Using a pin lock tool
Firstly, you need to identify the pins and the lock tab. The lock tab is a tiny mechanism that needs to be tripped from the front of the connector. You can use a modified dental tool or a very small screwdriver to release the lock tab. It is important to be gentle and careful during this step to avoid damaging the connector.
Once the lock tab is released, you can use a pin lock tool to unlock the pins. Insert the pin lock tool into the hole next to each pin. Make sure the tool is fully inserted before attempting to pull the pins out. You may need to apply some force to pull the pins out, but be careful not to damage the connector or the wires.
After removing the pins, it is crucial to make a diagram or take pictures of the pin arrangement. This will ensure that you can correctly reassemble the connector. Label each pin and its corresponding hole to avoid confusion during reassembly.
Additionally, some Harley models have small connectors that can be pulled through the bars without the need for disassembly. However, for larger connectors or more complex setups, the pin lock tool method may be necessary. It is always recommended to consult a professional or a Harley-Davidson service manual if you are unsure about the process or if you encounter any difficulties.
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Cutting and extending wires
Before cutting the wires, it is crucial to determine if your bike is apart or not. If the bike is not apart, it may be necessary to remove all the connectors in order to fit the bars, as some models may have small enough connectors that can simply be pulled through the bars.
If cutting and extending is the chosen method, it is important to take the necessary precautions. It is recommended to take pictures or make a diagram of the wiring setup before cutting, to ensure that the wires are properly reconnected in the correct order. An unfolded paper clip can be used to unlock the pins in the connectors, and a safety pin or needle can also be useful tools for this process.
After cutting the wires, they can be extended by soldering the ends and using adhesive-lined heat shrink tubing for insulation and protection. This method is preferred over crimping, as it provides a more reliable connection, especially with the vibrations of a motorcycle.
Additionally, when extending the wires, it is recommended to use 20-gauge wire to match the original wiring. This will ensure that the electrical system remains intact and functional.
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Unlocking pins with a paperclip
It is important to note that this process may take some time and effort, and it is recommended to take pictures or make a diagram of the pin configuration to ensure proper reassembly. This method can be used in conjunction with the cut and extend method, which involves cutting the wires and extending them to the desired length. However, this method requires skill and should be done properly to avoid any issues.
Some Harley-Davidson models have connectors that are small enough to pull through the bars without the need for depinning. However, for those models that do require depinning, the paperclip method is a simple and effective solution.
While the paperclip method is a viable option, some people prefer to use specific picks or tools designed for this purpose. These tools can be cheap and easily accessible, providing a quicker and more efficient way to unlock the pins. Ultimately, the choice of method depends on personal preference and the specific model of the Harley electrical connectors.
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De-pinning and re-pinning cables
Step 1: Gather Your Tools
Before you begin, make sure you have the necessary tools on hand. You will need a tool to release the pins holding the connectors together. This can be a specialised pin lock tool, a small screwdriver, a safety pin, a needle, or even a paper clip. A magnifying glass and a bright light source can also be helpful.
Step 2: Understand the Connector Type
Different connectors may have different methods of pin removal. For example, JAE MX19 connectors have a specific process described in their manual. Understanding the type of connector you are working with will help you know how to best approach the de-pinning process.
Step 3: Document the Pin Configuration
Before removing any pins, take clear pictures or create a diagram of the pin configuration. Note the colours and positions of each pin, as well as their corresponding holes. This will be crucial for re-assembling the connectors correctly.
Step 4: De-pinning
Using your chosen tool, carefully release the pins one by one. With your other hand, gently pull on the corresponding wire as you release each pin. Be careful not to use too much force to avoid damaging the cables.
Step 5: Re-pinning
When re-assembling the connectors, carefully line up the pins with their corresponding holes. Ensure that the pins are properly inserted into the back of the connector. You should hear a slight "click" once they are securely in place.
Step 6: Test the Connection
Once you have re-pinned the connectors, test the electrical connection to ensure it is functioning properly.
Remember, taking your time and working carefully is crucial to avoid damaging the cables or connectors. If you are unsure about the process, it is always best to consult a professional or someone with the necessary skill level.
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Squeezing and pulling grey and black tabs
To begin, locate the grey tab at the top of the connector. Pull the grey tab out slightly to release the lock. You may need to push or squeeze the grey tab to release it. Additionally, you might need to lift the black tabs. Once the tabs are released, pull the connector apart by pulling on both ends. It might require some force, but it should come apart easily once you get it right.
It is important to note that this process may vary slightly depending on the specific connector and model of your Harley-Davidson motorcycle. Always refer to the appropriate service manual or seek advice from a qualified electrician or mechanic if you are unsure.
Taking apart electrical connectors can be challenging, and it is recommended to have the necessary skills or seek professional assistance to avoid any damage to the electrical system. Before proceeding, ensure you have a basic understanding of electrical systems and connector types. Additionally, taking pictures or creating a diagram of the connector and its wiring can be helpful for reassembly.
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Frequently asked questions
You can use a pin lock tool, or a plastic straw (stiff and trimmed). An unfolded paperclip can also be used to unlock the pins in the connectors.
It is important to take pictures or make a diagram of exactly which pin goes into which hole so that you can put the connectors back together in the right order.
You can try pushing/squeezing the grey tab and/or lifting the black tabs before pulling them apart.
