buell s1 lightning '97 Manual

The Deutsch Connector features a superior seal to protect
electrical contacts from dirt and moisture in harsh environ-
ments. The connector also provides better pin retention than
previous connectors.

Three and eight pin connectors are of similar construction
with one exception: eight pin connectors use two external
latches on the socket side.

NOTE

wires. If new terminals must be installed, follow the instruc-
tions included with the crimping tool or see 

 on 

.

1.

See 

 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

2.

Gently depress terminal latches inside socket housing
(3) and back out socket terminals (1) through holes in
rear wire seal (2).

3.

Fit rear wire seal (2) into back of socket housing, if
removed. Grasp socket terminal approximately 1 in.
(25.4 mm) behind the contact barrel. Gently push sock-
ets through holes in wire seal into their respective cham-
bers. 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 confirm that it is properly locked in
place.

4.

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 fits into the center groove within the
socket housing and holds the terminal latches tightly
closed.

NOTE

●

The conical secondary locking wedge of the 3-pin con-
nector must be installed with the arrow pointing toward
the external latch. See 

●

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. 

1.

See 

 Remove the secondary locking wedge

(7). Use the hooked end of a stiff piece of mechanic’s
wire or a needle nose pliers, whichever is most suitable.

2.

Gently depress terminal latches inside pin housing (9)
and back out pin terminals (11) through holes in wire seal
(10).

3.

Fit wire seal (10) into back of pin housing (9). Grasp
crimped pin approximately 1 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 con-
firm that it is properly locked in place.

4.

Insert tapered end of secondary locking wedge (7) into
pin housing (9) and press down until it snaps in place.
The wedge fits in the center groove within the pin hous-
ing and holds the terminal latches tightly closed. 

Insert socket housing (3) into pin housing (9) until it snaps in
place. To fit 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.

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