Evening all,

Hope something like this hasn't been touched on, I tried doing a search.

After finally collecting all the parts I need so I can drop them off at the powdercoater, I learn last minute I need to remove and use my existing spot light assembly and not the used one I bought. Ok, no big deal, I've done the wiring on my older RK, has to be pretty much the same. I have to disassemble (of course) the whole thing for them to be able to powdercoat it. It's on the dining room table, I'm planning on properly removing the wiring from the connectors for a reliable re-install, and for the life of me I can't get the "tang" to release the wire so I can pull it out. I have the service manual and I check to see if anything has changed, doesn't seem so. It's not the Deustch or the Packard connector, it's the Metri Pak (sic?). It's only a 2-wire unit, the one for the spots. They even show you in the picture the approximate orientation when using the safety pin. There are two types of the same kind of connector, a push-to-release, and a pull-to-release. This one appears to be what I'm used to, the "pull" version. However, no matter which way, side, angle or depth, she just will not budge. (tried pushing just in case, no go) There are no clips to remove or anything of that nature that might stop it from releasing as it would on some of the other connectors, so after hours, yes hours, I walked away before I felt the need to start cutting!

The bike is an '09 with the regular everyday spotlights you'll find on any Ultra, etc. If you've found any 'secret', please post because if for no other reason, the guy doing my powdercoating is all set to go and now I'm holding him up due to these damn lights.

HUGE thanks for any help!!!

 

Does it look like this? Did you remove the end (B) to remove the wiring?

 

I'm at work so I don't have the factory manual in front of me, but I recall having the same problem with a Metri-Pak connector and spent at least an hour trying to remove the terminal from the plastic connector (I think that's what you are trying to do, right?)

You need to look VERY carefully at the end of the plastic connector to see where the tang is holding the terminal. To release the terminal, you need a very thin screwdriver (jeweler's screwdriver) to depress the plastic tang. I remember my conceptual problem at the time was that I was expecting to push the screwdriver pretty far into the connector, but the tang can and should be depressed with the screwdriver pretty near the end of the connector. In other words, you don't jam the screwdriver far into the connector, because that doesn't depress the tang properly to release the terminal. Also, think about which way the tang needs to move (because I can't visualize it at the moment.) It seems to me that the tang moved up (or down?) in the opposite direction of what originally seemed obvious to me.

When you do finally move the tang in the right direction and get it fully out of the way of the terminal, the terminal will move easily out of the connector and you'll say "Oh, s**t!"

 

Ya if it wasnt for my buddy I would have never gotten mine to come out either.

 

first, you have to open up the connector...it is either like the one posted above or hinged.
Then each pin has a locking tab (or 2) on the side in which must be depressed...a micro flat blade screwdriver will usually do the trick...if not then you need a pin tool as a last resort.

 

Hello once again Dawg, it's similar to the pic you have except there is no clip of any sort like that blue part shown behind the connector, and in your pic, there is a single release clip on the flat side of the connector. Mine, however, has two (much smaller) release clips on the sides of the connector. Funny thing is, in the manual, they mention something similar to what you have pictured, but there is NO clip or anything to be removed, released, opened, folded back, or anything. Quite simply a matter of fiddle with it until you hit the right spot to release the wire terminal.

Will try to put pics here.

Hope these come out. If they DO show up, yeah, I know, a little blurry!

 

Do I see something green in back in pic #3? If so, I believe that is like what are blue in the pic I posted and I believe you are going to have to remove that to get the wires out.

 

A small jeweler's screwdriver will work or use a large paper clip. A safety pin comes to a point and does not work. I used a paper clip and it worked fine. Push the wire with inward pressure, insert paper clip end in the holes at the outside front of the connector, then pull wire out. Hope this helps.

 

Where are you located? Maybe I could swing by, give you a hand...B.

 

First things first, the help shown is very much appreciated!

I'll try to answer in the order posted;

"timvan first, you have to open up the connector"
Nothing to "open up", but I know which 'other' connector you're referring to.

"dawg Do I see something green in back in pic #3? If so, I believe that is like what are blue in the pic I posted and I believe you are going to have to remove that to get the wires out."
Yes to the green color, but sadly, no to that being any type of clip. That green color is the rubber seal that surrounds the wire when seated in the connector. Not only can you feel it with a small pick, they are two tiny individual pieces and that external clip is shaped entirely different. Weird huh?

"fireman54 A small jeweler's screwdriver will work or use a large paper clip. A safety pin comes to a point and does not work. I used a paper clip and it worked fine. Push the wire with inward pressure, insert paper clip end in the holes at the outside front of the connector, then pull wire out. Hope this helps."
Holy end-of-frustration-Batman!! Right as I was typing the previous replies and got down to yours, I thought "wait a minute, I tried the smallest jewelers screwdriver I have, was so tight I switched to a safety pin". So, I got up to see exactly how small the screwdriver was (0.8 mm by the way) and curiosity got the best of me. I thought if this guy does it and it works fine, then just for the hell of it I'm going to jam that damn screwdriver in that same slot I was using just to see what happens. Granted, that kind of curiosity doesn't always yield great results, but this time I heard a fairly loud click (actually DID think I just broke something) and the wire .................. came right out!!!!
I knew I had to be close considering all the connectors I've fiddled with before, but I wasn't quite there. Seems the manual is not right. Not only does it show to use a safety pin, but it has you moving the pin from left-to-right so-to-speak within that cavity I using, AND you wouldn't be able to "move" the screwdriver left-to-right if you wanted to. So fireman54, in a way you inspired me to simply jam that screwdriver in just to see what would happen. Glad I did, now I can take the assembly apart. However, after looking at the size of the terminal, I doubt I could get it through the hole in the washer & bolt that is part of the spotlight housing. At least I'm better than 1/2 way there! Like I said to everyone here at first post H-U-G-E Thanks!! (see pic)

"bradssg Where are you located? Maybe I could swing by, give you a hand...B." Cool offer, thank you. So. Fla., and now that I actually managed to get it (see above), I'm good to go! But again, thank you.