I am making some modifications to my 1991 Sportster that hopefully will include relocation of the tach/speedo mount. I need to remove the indicator lights from the tach/speedo bracket to do a mock up of my plan.

Per the shop manual, I should first "disconnect light leads from connector mount in headlight...". I am not familiar with the older style connector and the manual from 1991 does not explain how to disconnect, just that you need Terminal Tool HD-97364-71.

I have gotten pretty good with the connectors on my 97 and 05, but this older version is new to me. So any direction on how to get it apart would be greatly appreciated. I am surprised how limited the information is on my older manual compared to the newer ones. The MoCo has made improvements.

 

There is a tiny tang on the connector ends that must be pressed in to remove the connector from the block...I use a tiny screw driver but it still sends me nuts at times.

 

If you don't want to buy the expensive tool you can use a small paper clip.
Straighten it out and fold it over once.
Push the wire into the connector then insert the flattened paper clip on the opposite side of the gap in the connector ( that will depress the tang spanners is talking about) then pull the wire out of the connector.

You have to push the wire into the connector first so that the tang doesn't get hung up inside the connector.

 

OK this sounds like the connectors on my 97. On the newer models you insert the tool from the socket side while you pull the wire out from the other side. On this white connector I do not see a place to insert the tool from the socket side, just the side that the wire exits. I hope that makes sense, if you need an image, I can make that happen later today.

 

You do it the same way on the white connectors.

You just have to use something very thin.

 

OK I am posting some images, insert a tool from the "connection" side is a no go with these older connectors.



There is room from the wire side, but there does not appear to be a tang inside:



Now what???

 

Using this tool:



I was able to remove the male side of the connector. Not working for the female side (go figure). I used the "tube", slid it over the male side and the tang on the connector retracted and the wire pulled out. Tried the same move on the female side, no luck.

Someone must have dealt with these connectors before??

 

You have to insert it from the connector side.
There is no way to access the tang from the wire side.

Do you remember that I said you need a small paperclip?
There is enough play in the end of the connector to get it in there.
It does work.. That is how I did it the first time.

 

THC, OK on the paperclip, am I going between the connector and the plastic OR down the middle of the connector? I am guessing the former, just checking.

 

You have to go down between the connector and the housing on the opposite side of the connector from the spit in the connector.