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ELECTRICAL CONNECTORS
GENERAL
The following table provides a description of the connectors found on your motorcycle. Connector numbers are listed in [brackets] in this manual. NOTE
B.1
Male ends of connectors are labeled A in text. Female ends of connectors are labeled B in text.
3-blade relay connector 4-place Deutsch 4-place Amp Multilock 12-place Packard 2-place barrel connector 2-place Amp Multilock
Under seat, to right of battery Behind windscreen Behind windscreen/headlamp On back of speedometer Above swingarm, left side On top of swingarm, cable tied to rear brake line Under seat on right side Under seat, to right of shock Under frame backbone at coil Under frame backbone, right side
9-slot fuse block 3-place Deutsch 3-place Amp Multilock 6-place Deutsch
Fuse Block Speed Sensor Ignition Coil Throttle Position Sensor and AutoEnrichener Clutch Switch Oil Pressure Switch
At left handlebar Above oil lter, right lower side of crankcase At switch, under frame by shock absorber At horn, behind front fork Under seat to right of battery Under starter solenoid Behind sprocket cover, right side Under Seat to right of battery At right handlebar switch Under seat, to left of battery Above sprocket cover, right side Appendix B: Wiring B-1
2 blades
Blade 4-blade relay connector Blade Post 3-place Packard 2 blades 4-blade relay connector 1-Place Bullet
Horn Starter Relay Starter Neutral Switch Bank Angle Sensor Front Brake Switch System Relay Neutral Switch to main harness
HOME
B.2
a0266x7x
11 10 9
8 7 6 5 4 2 1 3
Socket Side 1. 2. 3. 4. 5. 6. Socket Terminal Wire Seal Socket Housing External Latch Internal Seal Secondary Locking Wedge
Pin Side 7. Secondary Locking Wedge 8. Latch Cover 9. Pin Housing 10. Wire Seal 11. Pin Terminal
REMOVING/INSTALLING SOCKETS
1. See Figure B-1. Remove the secondary locking wedge (6). 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 to pop the wedge up. Gently depress terminal latches inside socket housing (3) and back out socket terminals (1) through holes in rear wire seal (2). Fit rear wire seal (2) into back of socket housing, if removed. Grasp socket terminal approximately 1.0 in. (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 conrm that it is properly locked in place. Install internal seal (5) on lip of socket housing, if removed. Insert tapered end of secondary locking wedge (6) into socket housing and press down until it snaps in place. The wedge ts into the center groove within the socket housing and holds the terminal latches tightly closed. NOTE
REMOVING/INSTALLING PINS
1. See Figure B-1. Remove the secondary locking wedge (7). Use the hooked end of a stiff piece of mechanics wire or a needle nose pliers, whichever is most suitable. Gently depress terminal latches inside pin housing (9) and back out pin terminals (11) through holes in wire seal (10). Fit wire seal (10) into back of pin housing (9). Grasp crimped pin approximately 1.0 in. (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 conrm that it is properly locked in place. Insert tapered end of secondary locking wedge (7) into pin housing (9) and press down until it snaps in place. The wedge ts in the center groove within the pin housing and holds the terminal latches tightly closed.
2.
2. 3.
3.
4.
4.
ASSEMBLY/INSTALLATION
Insert socket housing (3) into pin housing (9) until it snaps in place. To t the halves of the connector together, the latch (4) on the socket side must be aligned with the latch cover (8) on the pin side.
The conical secondary locking wedge of the 3-pin connector must be installed with the arrow pointing toward the external latch. See Figure B-2. 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.
CRIMPING INSTRUCTIONS
1. See Figure B-3. Squeeze the handles to cycle the DEUTSCH TERMINAL CRIMP TOOL (Part No. HD39965) to the fully open position.
B-2
Appendix B: Wiring
HOME 2. Raise locking bar by pushing up on bottom ange. With the crimp tails facing upward and the rounded side of the contact barrel resting on the concave split level area of the crimp tool, insert contact (socket/pin) through middle hole of locking bar. 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 ts snugly in the space between the contact band and the core crimp tails. Strip lead removing 0.1562 in. (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. Squeeze handle of crimp tool until tightly closed. Tool automatically opens when the crimping sequence is complete. Raise up locking bar and remove contact. Figure B-2. 3-pin Locking Wedge Orientation NOTE Inspect the quality of the core and insulation crimps. Distortion should be minimal.
a0267x7x
3.
Pin Housing
4.
Socket Housing
5.
1.
2.
3.
Locking bar
4.
5.
a0268x7x
Appendix B: Wiring
B-3
HOME
B.3
1
4 2 1
1. 2. 3. 4. 5. Secondary Lock Open Latch Socket Housing Socket Terminal Button
7.
1 3
NOTE An AMP TERMINAL CRIMP TOOL (Part No. HD-41609) is used to install Amp Multi-lock pin and socket terminals on wires. If new terminals must be installed, see CRIMPING INSTRUCTIONS.
1. 2. 3. 4.
Secondary Lock Open Latch Pin Housing Pin Terminal Figure B-5. Pin Housing
B-4
Appendix B: Wiring
HOME
a0271x7x
3 1 C 2 A
NOTES For wire location purposes, numbers are stamped into the secondary locks of both the socket and pin housings. 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. From the secondary lock side of the connector, insert the terminal into its respective numbered chamber until it snaps in place. For proper t, the slot in the terminal must face the tang in the chamber. a. b. If installing socket terminals, see Figure B-6. If installing pin terminals, see Figure B-7.
1. 2. 3.
Secondary Lock Open Socket Housing Socket Terminal Figure B-6. Socket Terminals
1.
a0272x7x
3 C
2. 3. 4. 5.
Gently tug on wire end to verify that the terminal is locked in place and will not back out of chamber. Rotate the hinged secondary lock inward until tabs fully engage latches on both sides of connector. Insert the socket housing (plug) into the pin housing (receptacle) until it snaps in place. Secure wiring harness with new cable straps.
B
1. 2. 3. Secondary Lock Open Pin Housing Pin Terminal Figure B-7. Pin Terminals
Appendix B: Wiring
B-5
HOME
CRIMPING INSTRUCTIONS
1. See Figure B-9. Squeeze the handles to cycle the AMP TERMINAL CRIMP TOOL (Part No. HD-41609) to the fully open position. Raise locking bar by pushing up on bottom ange. 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. Release locking bar to lock position of contact. When correctly positioned, the locking bar ts snugly in the space at the front of the core crimp tails. Strip lead removing 0.1562 in. (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. Squeeze handle of crimp tool until tightly closed. Tool automatically opens when the crimping sequence is complete. Raise up locking bar and remove contact. See Figure B-8. Inspect the quality of the core and insulation crimps. Distortion should be minimal.
a0273x7x
1.
2.
Raise locking bar and seat contact on nest of crimp tool. Release locking tool.
3.
4.
2.
5.
6.
3.
a0274x7x
squeeze
1 2 3
Pin Terminal
4
4. Raise locking bar and remove contact
Socket Terminal
1. 2. 3. 4.
Insulation Crimp Tail Core Crimp Tail Locking Groove Bar Tang Slot Figure B-8. Crimps
B-6
Appendix B: Wiring
HOME
a0280a7x
TRIP RESET SWITC H TRIP RESET NEUTRAL RIG TURN HT OIL NO USED T HIG BEAM H LEFT TURN G ROUND VEH SPD SIGN AL SPD SENSOR PWR SPD SENSOR RETURN ACC ESSORY 1 2 3 4 5 6 7 8 9 10 11 12
SPARK PLUG
134
BANK ANGLE SENSOR
10
INTEG RATED ELEC TRONI IGNI ION C T MODULE
6 5 4 3 2 1
83
THROTT LE POSITION SENSOR IGNI ION T C OIL
C B A
AUTO ENRIC H
O
BK LBE Y
22
IGNPOWER IGNMODULE FROM(3) TOSTART RELAY ACC POWER TOSTOPLIGHT BE W/R GN /BK Y/R 4 3 2 1 G Y W/BK W/BK BK/R
e
TN GN /Y
c
6 5 4 3 2 1
R/Y
b'
f d c c b
LGN Y /G PK V/O V/W W/BK W/BK
c a a
TWISTED TRIPLET
BK V/W V/W
BK
BK
PK
39
12 11 10 9 8 7 6 5 4 3 2 1
C B A
W/BK TN/Y LGN Y /G
V/O
u b
p a ba a e
d b S14
172
NEUTRAL SWITC H OIL PRESSURE SWITC H REAR STOPLIGHT SWITC H
W/BK 1
d
TN BK W
BRAKE SWITC H
B A
GN /Y
SPEED SENSOR
BN O/W
R/Y
R/Y
65
BK
b b b
f c b
d a ac d c c
131
120
121
170
b S8
t
BK
TN/W
a a S6 b SIDESTAND SWITC H
1 2
BE
BK
60
e
BK W
BN BK
LT. BE
BE
BN O/W V R/Y
e e e c m
O/W W Y BK
W Y BK
2 3 4
d c b e
b S9
BK
1 2 3 4 5 6
BN O/W V R/Y BK
c R/Y n BK S2
38
S4 HEADLAMP b b S12 S1 LEFT FRON T DIREC TION AL LAMP
LT. BE
V
7
h
O/W
a c
S5 b
e o
BE
BK
V BK
R/BK
BE
24
LOW BEAM LIGHT POWER HIG BEAM H HORN FROMFLASHER LEFT TURN RIG TURN HT HORN POWER W BN BK GN BE O LBE G Y 1 2 3 4 5 6 7 8 9 Y BE W Y/BK V/BN V BN O
R R
S3 b
a b a a a d d g b
R/BK1
S13
R/BK1
S11 d a
b MASTER C /B ca e
R2 R/BK R/G Y R2
a
BK R
KEY SWITC H
SYSTEM
LIGHTS
15A
15A
15A
k
TOGND FROM START RELAY R/BE BK 1 2 BK TN/GN
a j
BK
BE
O R2
b b*
D C B A
128
a
30A
e
GN BK
A B C D E F BK 2
DIODE1
SPARE
15A
DIODE2
C LUTC SWITC H H LEGEND : IGNI IONC UIT T IRC STARTINGC UIT IRC FLASHER
Y R
Y/BK
G Y
95
HORN
TN/W
TN/Y
TN/Y
GN/B K
122
33
b*
TN/GN TN/GN R/BK
123
86 85 87 30 87A STARTER RELAY c b
R1
R1
b
R
db b c
TN/GN GN BK/R
TN
BK 3 BK 3
b d
b e
d b S7
R/G Y
R/B 1
46
C HARGING IRC C UIT C OLO C R ODE : l BE BLUE BK BLAC K BN BROWN GN G REEN G G Y RAY O ORANGE PK PINK R RED TN TAN V VIOLET W WHITE Y YELLOW LT. LIGHT
BK
171
R/BK
a d
86
85
61
O/W G Y
da
BK
KEY SWITC H
V/BN
30
f
O
b
R
BK R/BK1
BK
16 R 2 A 16 R D 16 G Y
BATT ERY
STATOR
PARK LOC K
6A RATING
ON
6A RATING
D 16 GN /B
E 16 Y
C 16 R/BK
B 18 O/W
Figure B-10. 2001 Buell Blast P3 Model - Main Harness Appendix B: Wiring B-7
HOME
a0194x5x
COLOR LT. BK BE BN GN GY O PK R TN V W Y CODE: LIGHT BLACK BLUE DIODE BROWN GREEN GRAY ORANGE PINK RED TAN VIOLET WHITE YELLOW NO CONNECTION SPLICE CONNECTION SOCKET CONNECTOR PIN CONNECTOR CONNECTOR CODE:
22
A 16 R
4 3 2 1
PARK LOCK
OFF
ON
R R
SYSTEM
LIGHTS
15A
15A
15A
R2 R/BK
R/BE BK
1 2
BK TN/GN
R2
R2
D C B A
128 123
86 85 87 30
R1
DIODE 1
SPARE
15A
CLUTCH SWITCH
DIODE 2
33
TN/GN TN/GN R/BK
GY
95
GN/B K
R1
Y R
BK/R R/B 1
TN/GN GN
ACCESSORY
IGNITION
SPARE
7.5A
7.5A
7.5A
171
R/BK R
86
85 87
61
GY
BK R/BK1
BATTERY
Figure B-11. 2001 Buell Blast P3 Model - Starting B-8 Appendix B: Wiring
30A
HOME
a0278x7x
COLOR CODE: LT. BK BE BN GN GY O PK R TN V W Y LIGHT BLACK BLUE DIODE BROWN GREEN GRAY ORANGE PINK RED TAN VIOLET WHITE YELLOW NO CONNECTION SPLICE CONNECTION SOCKET CONNECTOR PIN CONNECTOR CONNECTOR CODE:
BK R
128
R1
BK R BK 3 BK 3
30A
R1
BK 2
46
BK
BK
Appendix B: Wiring
B-9
HOME
16 R
PARK LOCK
6A RATING
OFF
ELECTRONIC SPEEDOMETER
16 GY
a0279x7x
TRIP RESET NEUTRAL RIGHT TURN OIL NOT USED HIGH BEAM LEFT TURN GROUND VEH SPD SIGNAL SPD SENSOR PWR SPD SENSOR RETURN ACCESSORY
1 2 3 4 5 6 7 8 9 10 11 12
16 R 2 A D
GN/Y
ON 12A RATING 6A RATING
D 16 GN/B
E 16 Y
TN
B 18 O/W
COLOR LT. BK BE BN GN GY O PK R TN V W Y
16 R/BK
39
172
NEUTRAL SWITCH
BLUE DIODE BROWN GREEN GRAY ORANGE PINK RED TAN VIOLET WHITE YELLOW NO CONNECTION SPLICE CONNECTION SOCKET CONNECTOR PIN CONNECTOR
B A
W R
BK GN/Y
V W BN
TN
O/W
BLACK
65
BK
120
131
24
1 2 HIGH BEAM HORN LEFT TURN RIGHT TURN HORN POWER BK GN O LBE GY 3 4 5 6 7 8 9 V BN W R/B 1 Y/BK
MASTER C/B
GN
SYSTEM
LIGHTS
KEY SWITCH
15A
15A
15A
R/BK
R/GY
O R2 D C B A
R2
122
TN/Y
GN/B K
BK
128
R1
BK
R1
DIODE 1
SPARE
DIODE 2
R/GY
ACCESSORY
IGNITION
SPARE
7.5A
171
R/BK R
7.5A
7.5A
15A
86
85 87
KEY SWITCH
BK R/B 1 O/W
B-10
Appendix B: Wiring
Y R
HORN
Y/BK
33
30A
HOME
COLOR LT.
CODE:
16 R
CONNECTOR
CODE:
a0281x7x
TRIP RESET NEUTRAL RIGHT TURN OIL NOT USED HIGH BEAM LEFT TURN GROUND VEH SPD SIGNAL SPD SENSOR PWR SPD SENSOR RETURN ACCESSORY 1 2 3 4 5 6 7 8 9 10 11 12
BK BE BN GN GY O PK R TN V W Y
DIODE BROWN GREEN GRAY ORANGE PINK RED TAN VIOLET WHITE YELLOW NO CONNECTION SOCKET CONNECTOR PIN CONNECTOR
PARK LOCK
OFF
ON
SPLICE
CONNECTION
ZADI KEY SWITCH
O
B 18 O/W
C 16 R/BK
ELECTRONIC SPEEDOMETER
R/Y
12 11 10 9 8 7 6 5 4 3 2 1
39
W/BK 1
R/Y
R/Y
W BN BK V
BRAKE SWITCH
121
170
R/BK
BN
BE
BK
BN BK
LT. BE
BE
BN O/W V R/Y
O/W W Y BK
1 2 3 4
O/W W Y BK
BK
1 2 3 4 5 6
BN O/W V R/Y BK
38
HEADLAMP
R/Y BK O/W
LT. BE
V V BK
R/BK
BE
BE
BK
24
LOW BEAM LIGHT POWER HIGH BEAM W BN BK 1 2 3 4 5 6 7 8 9 Y BE W R/BK1 R/BK1
R R
BE O LBE
V/BN V BN
KEY SWITCH
MASTER C/B
R1
BK
SYSTEM
LIGHTS
15A
15A
15A
R2 R/BK
R/GY
BE
O R2 D C B A
R2
128
GN/B K
R1
DIODE 1
SPARE
DIODE 2
FLASHER
R/GY
ACCESSORY
IGNITION
SPARE
7.5A
BK
171
R/BK
7.5A
7.5A
15A
33
GY
86
85 87
61
O/W
KEY SWITCH
BK R/BK1
V/BN
30
O
Y R
BATTERY
30A
HOME
a0282a7x
SPARK PLUG
134
BANK ANG LE SENSOR
10
INTEG RATED ELEC TRONI IGNI ION C T MODULE
6 5 4 3 2 1
83
THROTT LE POSITION SENSOR IGNI ION T C L OI
C B A
AUTO ENRIC H
BK LBE Y
22
IGNPOWER IGNMODULE FROM (3) BE W/R GN /BK 4 3 2 1 G Y W/BK W/BK
TN
6 5 4 3 2 1
LGN Y /G PK V/O
V/W W/BK
W/BK
BK V/W V/W
BK
BK
PK
C B A
W/BK TN/Y LGN Y /G
V/O
172
NEUTRAL SWITC H
S14
131
BK
16 R 2 A 16 R D 16 G Y
TN/W
1 2
60
SIDESTAND SWITC H
BK
PARK LOC K
6A RATING
OFF
ON
12A RATING
6A RATING
D 16 GN /B
E 16 Y
C 16 R/BK
B 18 O/W
R R
R/B 1
KEY SWITC H
MASTER C /B
SYSTEM
LIGHTS
15A
15A
15A
R2 R/BK
R/BE BK
1 2
BK TN/GN
O R2 D C B A
R2
128
R1
G Y
95
CL UTC SWITC H H
TN/Y TN/W
TN/Y
GN/B K
R1
DIODE 1
DIODE 2
SPARE
TN
15A
33
TN/GN R/BK
IGNI ION T
ACC ESSORY
7.5A
7.5A
171
R/BK R
SPARE
7.5A
86
85 87
61
G Y
KEY SWITC H
BK R/BK1
BATTERY
B-12
Appendix B: Wiring
30A