Harness plug stopping my project!
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Tourer
Joined: Apr 2012
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From: Goodyear, Az
Harness plug stopping my project!
I thought I'd post this on the Dyna Forum, if you don't mind...
Try to replace the headlight harness on the wife's Sportster (one step in installing a Ness fairing), and my progress came to a stop, trying to disassemble this three-wire harness plug.
I've had to pull apart larger ones, on my Dyna, (that use release clips) but this one's got me stumped. Is there a trick to getting the wire ends out in one piece, or is it just a matter of brute force? (You can see in the photo, I've already swung away the plastic clip at the end.)
Try to replace the headlight harness on the wife's Sportster (one step in installing a Ness fairing), and my progress came to a stop, trying to disassemble this three-wire harness plug.
I've had to pull apart larger ones, on my Dyna, (that use release clips) but this one's got me stumped. Is there a trick to getting the wire ends out in one piece, or is it just a matter of brute force? (You can see in the photo, I've already swung away the plastic clip at the end.)
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From: the 50s & the 60s
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have a look here.
near the end there are two videos..................................
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have a look here.
near the end there are two videos..................................
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Seasoned HDF Member
Joined: Dec 2010
Posts: 6,850
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From: Florida
I just used a paper clip and gently move the two pieces holding the plug end in and then it just comes out. You have to repeat the process for each wire. I believe you get the clips out o the way from the top
Road Master
Joined: Aug 2013
Posts: 1,083
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From: South Central Va
A screwdriver for a pair of glasses works much easier on that type of plug, the sharp edge will go under the clip much easier than a paper clip. Go in form the wire side of the plug and look for the plastic tab that holds the metal connector in, and lift it with the screwdriver. Once you get the angle right it's a breeze.
Last edited by Ndfastln; Dec 13, 2013 at 11:50 PM.
A screwdriver for a pair of glasses works much easier on that type of plug, the sharp edge will go under the clip much easier than a paper clip. Go in form the wire side of the plug and look for the plastic tab that holds the metal connector in, and lift it with the screwdriver. Once you get the angle right it's a breeze.
Outstanding HDF Member
Joined: Dec 2012
Posts: 2,557
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From: Texas
this is how electrical problems start...
I have well over 25 years experience with aircraft wiring fabrication, modifications, and repairs and a lot of expensive wire and connector repair tools in my tool inventory and know how to use them in just about any application you can imagine.
Keep in mind...if you break the fragile plastic contact latch on the connector housing, you will have to replace it. If you damage break the thin metal contact latch tabs on the contact, you will have to crimp on a new contact so you will need the proper crimp tool to do it right.
However, since you only have three wires, if you just stagger cut the wires about 6 inches or so back from the plug and splice them back together using uninsulated barrel splices and heat shrink (not plastic coated butt splices), you have not compromised the mechanical or circuit integrity of the connector or contacts. I have used this method with great success thousands of times and it is the method I would use here because, based on experience, it is the fastest and most secure with less chance for future problems.
Good luck.
Keep in mind...if you break the fragile plastic contact latch on the connector housing, you will have to replace it. If you damage break the thin metal contact latch tabs on the contact, you will have to crimp on a new contact so you will need the proper crimp tool to do it right.
However, since you only have three wires, if you just stagger cut the wires about 6 inches or so back from the plug and splice them back together using uninsulated barrel splices and heat shrink (not plastic coated butt splices), you have not compromised the mechanical or circuit integrity of the connector or contacts. I have used this method with great success thousands of times and it is the method I would use here because, based on experience, it is the fastest and most secure with less chance for future problems.
Good luck.
As an addition to previous tips (mud, Ndfastln, misfitJason) check out this image on the use of a jewlers screwdriver or a one end flattened paperclip:
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