REMOVING SOCKET/PIN TERMINALS INSTALLING ...mael.rivoal.free.fr/Manuel Buell XB9R/sm_appb1.pdf2004 Buell Firebolt: Appendix B B-1 HOME 73 AMP MULTILOCK ELECTRICAL CONNECTORS B.1 REMOVING

2004 Buell Firebolt: Appendix B B-1

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73

AMP MULTILOCK ELECTRICAL CONNECTORS B.1

REMOVING SOCKET/PIN

TERMINALS

1. Remove connector from the retaining device, eitherattachment or rosebud clip.

2. Depress the button on the socket terminal side of theconnector (plug) and pull apart the pin and sockethalves.

3. Bend back the latch slightly and free one side of second-ary lock, then repeat the step to release the other side.Rotate the secondary lock outward on hinge to accessterminals in chambers of connector housing.

4. Looking in the terminal side of the connector (oppositethe secondary lock), take note of the cavity next to eachterminal.

5. See Figure B-1. With the flat edge against the terminal,insert the pick tool (Snap-On TT600-3) into the cavityuntil it stops. Pivot the end of the pick away from the ter-minal (locktab is inside housing) and gently tug on wire topull terminal from chamber. Do not tug on the wire untilthe tang is released or the terminal will be difficult toremove. A “click” is heard if the tang is engaged but then

inadvertently released. Repeat the step without releasingthe tang.

NOTES

●

If pick tool is not available, a push pin/safety pin may beused instead.

●

An ELECTRICAL TERMINAL CRIMP TOOL (Part No.HD-41609) is used to install Amp Multi lock pin andsocket terminals on wires. If new terminals must beinstalled, see Crimping Instructions on the next page.

INSTALLING SOCKET/PIN

TERMINALS

NOTEFor wire location purposes, numbers are stamped into thesecondary locks of both the socket and pin housings. SeeFigure B-2.

1. From the secondary lock side of the connector, insert theterminal into its respective numbered chamber until itsnaps in place. For proper fit, the slot in the terminalmust face the tang in the chamber.

Figure B-1. 10-Place Amp Multilock Connector

d0242x3x

Secondary lock open

Secondary lock open

Pin housing

Latch

Pin terminal

Socket housing

Secondary lock open

Socket terminal

Button

Latch

Latch

B-2 2004 Buell Firebolt: Appendix B

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NOTES

●

See Figure B-3. The tang in the chamber engages theslot to lock the terminal in position.

●

On the pin side of the connector, tangs are positioned atthe bottom of each chamber, so the slot in the pin termi-nal (on the side opposite the crimp tails) must face down-ward.

●

On the socket side, tangs are at the top of each chamber,so the socket terminal slot (on the same side as thecrimp tails) must face upward.

●

Up and down can be determined by the position of therelease button (used to separate the pin and sockethalves). Consider the button to always be on top of theconnector.

2. Gently tug on wire end to verify that the terminal islocked in place and will not back out of chamber.

3. Rotate the hinged secondary lock inward until tabs fullyengage latches on both sides of connector.

4. Insert the socket housing (plug) into the pin housing(receptacle) until it snaps in place.

5. Install connector on retaining device, either attachmentor rosebud clip.

Figure B-2. Release Tang and Back Out Terminals

2

1

3

4

4

1

2

3

Pin terminal

Socket terminal

Secondary lock open

Secondary lock open

Pick tool

Pick tool

Pin housing

Socket housing

1. Open secondary lock.2. Insert pick into cavity on inboard side

of connector.3. Pivot end of pick to release tang.4. Gently tug on wire to remove terminal

from housing.

d0243x8x

Figure B-3. Multilock Connector Cutaway View

Pin housing

Tang

Socket housing

Tang

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Button


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Figure B-4. 3-Place and 6-Place Amp Multilock Connectors

– AMP

1 2 3– AMP

1 2 3 4 5 6 5 6 7 8 9 10

4321

Socket terminal

Secondary lock

Socket housing

Pin housing

Pin terminal

Latch

Secondary lock

Button

Latch

Socket terminal

Secondary lock

Button

Socket housing

Pin housing

Secondary lock

Pin terminal

3-place 6-place 12-place

Secondary locks open (socket housings shown)

Stamped numbers on secondary locks indicate wire color locations

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CRIMPING INSTRUCTIONS

1. Squeeze the handles to cycle the crimp tool (Part No.HD-41609) to the fully open position.

2. Raise locking bar by pushing up on bottom flange. Withthe crimp tails facing upward, insert contact (socket/pin)through locking bar, so that the closed side of the contactrests on the front nest (concave split level area of thecrimp tool). See Figure B-3.

3. Release locking bar to lock position of contact. Whencorrectly positioned, the locking bar fits snugly in thespace at the front of the core crimp tails.

4. Strip lead removing 5/32 in. (4 mm) of insulation. Insertwires between crimp tails until ends make contact withlocking bar. Verify that wire is positioned so that shortpair of crimp tails squeeze bare wire strands, while longpair folds over insulation material.

5. Squeeze handle of crimp tool until tightly closed. Toolautomatically opens when the crimping sequence iscomplete. Raise up locking bar and remove contact.

6. Inspect the quality of the core and insulation crimps. Dis-tortion should be minimal.

Figure B-5. Amp Multilock Crimping Procedure

1. Raise locking bar and seat contact on front nest of crimp tool. Release locking bar

2. Insert stripped lead until it contacts locking bar.

3. Close and squeeze crimp tool. 4. Raise locking bar and remove contact.

1. Insulating crimp tail2. Core crimp tail3. Locking bar groove4. Tang slot

21

3

4

43

12

d0246x8x

GAUGE WIRE

CRIMP TOOL NEST

20 Front

16 Middle

18 Rear


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DEUTSCH ELECTRICAL CONNECTORS B.2

GENERAL

Deutsch Connectors feature a superior seal to protect electri-cal contacts from dirt and moisture in harsh environments.The connector also provides superior pin retention.

See Figure B-8. This 12-pin connector illustrates the variousparts of the Deutsch connector. The following instructionsmay be followed for all 2-pin through 12-pin Deutsch connec-tors.

Socket housing:

alignment tabs and/or external latch, sec-ondary locking wedge, internal seal, wire seal, seal pin.

NOTE

Seal pins or plugs are installed in the wire seals of unused pinand socket locations. If removed, seal pins must be replacedto maintain the integrity of the environmental seal.

Pin housing:

alignment grooves and/or external latch cover,attachment clip, secondary locking wedge, wire seal, seal pin.

REMOVING/DISASSEMBLING

Attachment clips are attached to the pin housings of mostconnectors. The clips are then attached to T-studs on themotorcycle frame. T-studs give positive location to electricalconnectors and wire harness. Consistent location reduceselectrical problems and improves serviceability.

1. Push the connector to disengage small end of slot onattachment clip from T-stud. Lift connector off T-stud.

2. Depress the external latch(es) on the socket housingside and use a rocking motion to separate the pin andsocket halves. Two-, three-, four- and six-pin Deutschconnectors have one external latch, while eight- andtwelve-pin connectors have two, both of which must bepressed simultaneously to separate the connectorhalves.

NOTE

With few exceptions, the socket housing can always be foundon the accessory side, while the pin side of the connector isconnected to the wiring harness.

REMOVING/INSTALLING SOCKETS

1. See Figure B-7. Remove the secondary locking wedge.Insert the blade of a small screwdriver between thesocket housing and locking wedge inline with the groove(inline with the pin holes if the groove is absent). Turn thescrewdriver 90 degrees to pop the wedge up.

2. See Figure B-8. Gently depress terminal latches insidesocket housing and back out sockets through holes inrear wire seal.

NOTEAn ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD-39965) is used to install Deutsch pin and socket terminals onwires. If

new

terminals must be installed, follow the instruc-tions included with the crimping tool or see Crimping Instruc-tions in this section.

Fit rear wire seal into back of socket housing, if removed.Grasp socket approximately 1.0 in. (25.4 mm) behind thecontact barrel. Gently push sockets through holes in wire sealinto their respective chambers. Feed socket into chamberuntil it “clicks” in place. Verify that socket will not back out ofchamber; a slight tug on the wire will confirm that it is properlylocked in place.

Figure B-6. Remove Secondary Locking Wedge

Figure B-7. Depress Terminal Latches/Back Out Pins

4566

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3. Install internal seal on lip of socket housing, if removed.Insert tapered end of secondary locking wedge intosocket housing and press down until it snaps in place.The wedge fits into the center groove within the sockethousing and holds the terminal latches tightly closed.

NOTES

●

While rectangular wedges do not require a special orien-tation, the conical secondary locking wedge of the 3-pinconnector must be installed with the arrow pointingtoward the external latch. See Figure B-9.

●

If the secondary locking wedge does not slide into theinstalled position easily, verify that all terminals are fullyinstalled in the socket housing. The lock indicates whenterminals are not properly installed by not entering itsfully installed position.

REMOVING/INSTALLING PINS

1. Remove the secondary locking wedge. Use the hookedend of a stiff piece of mechanics wire a needle nose pli-ers, or a suitable pick tool (Part No. HD-41475-100). SeeFigure B-10.

2. Gently depress terminal latches inside pin housing andback out pins through holes in wire seal.

Figure B-8. 12-pin Deutsch Connector (Exploded View)

Wire seal

Pin housing

Locking wedge

Locking wedge

Internal seal

Socket housing

Wire seal

Socket terminal

Seal pin

External latch

Alignment tabs

Alignment grooves

Pinterminal

Latch cover

d0248x8x

Figure B-9. Depress Terminal Latches/Back Out Pins

Pinhousing

Sockethousing

Arrow points toexternal latch

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NOTEAn ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD-39965) is used to install Deutsch pin and socket terminals onwires. If

new

terminals must be installed, see CrimpingInstructions in this section.

3. Fit wire seal into back of pin housing. Grasp crimped pinapproximately 1.0 in. (25.4 mm) behind the contact bar-rel. Gently push pins through holes in wire seal into theirrespective numbered locations. Feed pin into chamberuntil it “clicks” in place. Verify that pin will not back out ofchamber; a slight tug on the wire will confirm that it isproperly locked in place.

4. Insert tapered end of secondary locking wedge into pinhousing and press down until it snaps in place. Thewedge fits in the center groove within the pin housingand holds the terminal latches tightly closed.

NOTES

●

While rectangular wedges do not require a special orien-tation, the conical secondary locking wedge of the 3-pinconnector must be installed with the arrow pointingtoward the external latch. See Figure B-9.

●

If the secondary locking wedge does not slide into theinstalled position easily, verify that all terminals are fullyinstalled in the pin housing. The lock indicates when ter-minals are not properly installed by not entering its fullyinstalled position.

ASSEMBLING/INSTALLING

1. Insert socket housing into pin housing until it snaps inplace. Two-, three-, four- and six-pin Deutsch connectorshave one external latch on the socket half of the connec-tor. To fit the halves of the connector together, the latchon the socket side must be aligned with the latch coveron the pin side.

For those connectors with two external latches (8-pinand 12-pin), a different system is used to preventimproper assembly. Align the tabs on the socket housingwith the grooves on the pin housing. Push the connectorhalves together until the latches “click.” If latches do notclick (latch), press on one side of the connector until thatlatch engages, then press on the opposite side toengage the other latch.

NOTEDeutsch connectors are color coded for location purposes.Those connectors associated with

left

side accessories, suchas the front and rear

left

turn signals, are

gray

. All other con-nectors, including those associated with right side accesso-ries, are black.

If it should become necessary to replace a plug or receptacle,please note that the 8-pin and 12-pin gray and black connec-tors are not interchangeable. Since location of the alignmenttabs differ between the black and gray connectors, plugs orreceptacles must be replaced by those of the same color. Ifreplacing both the socket and pin halves, then the black maybe substituted for the gray, and vice versa. The socket and pinhalves of all other connectors are interchangeable, that is, theblack may be mated with the gray, since the alignment tabsare absent and the orientation of the external latch is thesame.

2. See Figure B-11. Fit the attachment clip to the pin hous-ing, if removed. Place large end of slot on attachmentclip over T-stud on frame. Push assembly forward toengage small end of slot.

Figure B-10. Deutsch Connector Pick Tool(Part No. HD-41475-100)

Figure B-11. Attachment Clip Installation

5893

5892

5891

Lock tab

Lock bar

Pin housing

Attachment clip

Attachment clip installed


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1. See Figure B-12. Squeeze the handles to cycle the crimptool to the fully open position.

2. Raise locking bar by pushing up on bottom flange. Withthe crimp tails facing upward and the rounded side of thecontact barrel resting on the concave split level area ofthe crimp tool, insert contact (socket/pin) through middlehole of locking bar.

3. Release locking bar to lock position of contact. If thecrimp tails are slightly out of vertical alignment, the crimptool automatically rotates the contact so that the tailsface straight upward. When correctly positioned, thelocking bar fits snugly in the space between the contactband and the core crimp tails.

4. Strip lead removing 5/32 in. (4 mm) of insulation. Insertwires between crimp tails until ends make contact withlocking bar. Verify that wire is positioned so that shortpair of crimp tails squeeze bare wire strands, while longpair folds over insulation material.

5. Squeeze handle of crimp tool until tightly closed. Toolautomatically opens when the crimping sequence iscomplete. Raise up locking bar and remove contact.

6. Inspect the quality of the core and insulation crimps. Dis-tortion should be minimal.

Figure B-12. Deutsch Crimping Procedure

d0250x8x

Locking bar

1. Insert contact through middle hole in locking bar.

2. Insert stripped lead until it contacts locking bar.

3. Close and squeeze crimp tool 4. Raise locking bar and remove contact.

Insulation crimp Core crimp


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Figure B-13. 2-Pin, 3-pin and 4-pin Deutsch Connectors

1. Socket terminal2. Wire seal3. Socket housing4. External latch5. Internal seal6. Locking wedge

7. Locking wedge8. Latch cover9. Pin housing10. Wire seal11. Pin terminal

SOCKET SIDE PIN SIDE

1

2

4

5

6

7

89

1011

3

2-pin connector

1

2

4

3

56

7

8

1011

9

3-pin connector

1

2

4

56

7

8

9

1011

3

4-pin connector

d0251x3x


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PACKARD ELECTRICAL CONNECTORS B.3

GENERAL

From a servicing standpoint, there are two basic types ofPackard electrical connectors, those with pull-to-seat termi-nals and those with push-to-seat terminals.

Look into the mating end of the connector. If it appears thatthe terminal can be extracted from this side, then it is proba-bly the pull-to-seat type.

At least one Packard pull-to-seat terminal can be easily rec-ognized by the presence of a locking ear. The ear engages aslot in the connector housing and prevents the terminal frombeing removed from the wire end side of the connector. Theear also acts as a strain relief in the event that the wires arepulled and further inhibits movement of the terminal insidethe chamber. For an example of this type of connector, notethe MAP sensor connector [80].

Unlike most connectors, where the terminals are pulled outthe wire end of the connector, to remove the terminals fromthe pull-to-seat connectors, the terminal is pushed out themating end of the connector. Once a

new

terminal is crimpedonto the end of the wire, the wire is pulled to draw the termi-nal back inside the chamber of the connector housing.

Two types of Packard pull-to-seat electrical connectors areused. One type has an external latch to lock the pin andsocket halves together, while the other makes use of a wire-form. See Figure B-14. The manner in which the terminalsare picked differs between these two types of connectors, asfurther described below.

Figure B-14. Packard Connectors

A

Locate tang on latch side of chamber.

C

Push on wire end of lead to remove terminal.

B

Pivot end of pin to depress tang.

D

Raise tang and re-install terminal.

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PULL-TO-SEAT TERMINALS

Removing External Latch Type

To remove a pull-to-seat terminal from connectors with exter-nal latches, proceed as follows:

1. Remove the connector from the retaining device, ifpresent.

2. Bend back the external latch(es) slightly and separatethe pin and socket halves of the connector.

3. To free a pull-to-seat terminal from the connector hous-ing, first look into the mating end of the connector to findthe locking tang. See A in Figure B-14. The tangs arealways positioned in the middle of the chamber and areon the same side as the external latch. On those connec-tors with locking ears, the tang is on the side oppositethe ear.

4. At a slight angle, gently insert the point of a one inchsafety pin down the middle of the chamber (about 1/8inch) and pivot the end of the pin toward the terminalbody. When a click is heard, remove the pin and repeatthe procedure. See B in Figure B-14. The click is thesound of the tang returning to the locked position as itslips from the point of the pin. Pick at the tang in thismanner until the clicking stops and the pin seems to slidein at a slightly greater depth than it had previously. This isan indication that the tang has been depressed.

NOTES

●

On those terminals that have been extracted on a previ-ous occasion, no clicking sound may be heard when thepin is pivoted to depress the tang, but proceed as if theclicking is audible and then push on the wire end of thelead to check if the terminal is free.

●

When picking multiple terminals, the end of the pin maybecome malleable. For best results, continue the proce-dure with a new safety pin.

5. Remove the pin and push on the wire end of the lead toextract the terminal from the mating end of the connec-tor. See C in Figure B-14. If necessary, pull back the con-duit and remove the wire seal at the back of theconnector to introduce some slack in the wires.

NOTEA series of Packard Electrical Terminal Crimp Tools are avail-able to install Packard pin and socket terminals on wires. If

new

terminals must be installed, see Crimping Instructions.

Installing External Latch Type

NOTEFor wire location purposes, alpha characters are stampedinto the socket housings.

1. To install a terminal back into the chamber of the connec-tor housing, use a thin flat blade, like that on an X-Actoknife, and carefully bend the tang outward away from theterminal body. See D in Figure B-14.

2. Gently pull on the lead at the wire end of the connector todraw the terminal back into the chamber. A click is heardwhen the terminal is properly seated.

3. Push on the lead to verify that the terminal is locked inplace.

4. Push the pin and socket halves of the connector togetheruntil the latches “click.”


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PUSH-TO-SEAT TERMINALS

The Packard push-to-seat terminal connectors are Buell Fire-bolts.

Removing Push-to-Seat Terminals

Like most connectors, Packard push-to-seat terminals arepulled out the wire end of the connector. To remove a push-to-seat terminal, proceed as follows:

1. Remove the connector from the retaining device, ifpresent.

2. Bend back the external latch(es) slightly and separatethe pin and socket halves of the connector.

NOTEBoth the Ignition Light/Key Switch and the Main Power con-nectors are provided with secondary locks. The secondarylock, which may be molded onto the connector or exist as aseparate piece, aids in terminal retention. Secondary locksmust be opened (or removed) before the terminals can beextracted from the connector housing.

3. Open or remove the secondary lock. Bend back the latchslightly and free one side of the secondary lock, thenrepeat the step to release the other side. Rotate the sec-ondary lock outward on hinge to access the terminals inthe chambers of the connector housing.

4. Looking in the mating end or terminal side of the connec-tor (opposite the secondary lock), take note of the largercavity next to each terminal.

5. Insert the pick (Snap-On TT600-3) into the cavity until itstops. Pivot the end of the pick toward the terminal todepress the locking tang. Remove the pick and gentlytug on the wire to pull the terminal from the wire end ofthe connector. Repeat the step if the terminal is stilllocked in place.

NOTEA series of Packard Electrical Terminal Crimp Tools are avail-able to install Packard pin and socket terminals on wires. Ifnew terminals must be installed, see Crimping Instructions.

Installing Push-to-Seat Terminals

NOTEFor wire location purposes, alpha characters are stampedonto the secondary locks or onto the wire end of the connec-tor housing.

1. To install a terminal back into the chamber of the connec-tor housing, use a thin flat blade, like that on an X-Actoknife, and carefully bend the tang outward away from theterminal body.

2. Push the lead into the chamber at the wire end of theconnector. A click is heard when the terminal is properlyseated.

3. Gently tug on the wire end to verify that the terminal islocked in place and will not back out of the chamber.

4. Close or install the secondary lock. Rotate the hingedsecondary lock inward until tabs fully engage latches onboth sides of connector.

5. Push the pin and socket halves of the connector togetheruntil the latches “click.”

6. Install connector on retaining device, if present.


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1. Strip wire lead removing 5/32 in. (4 mm) of insulation.

2. Compress handles until ratchet automatically opens.

NOTE

Always perform core crimp before insulation/seal crimp.

3. See Table B-1. Determine the correct dye or nest for thecore crimp.

NOTE

When the word “TIP” appears in the Crimp Table, use the tipof the tool specified to perform the core crimp procedure. SeeFigure B-15.

4. Lay the back of the core crimp tails on the appropriatenest. Be sure the core crimp tails are pointing towardsthe forming jaws.

5. Gently apply pressure to handles of tool until crimpersslightly secure the core crimp tails.

6. Insert stripped wire between crimp tails. Verify that wireis positioned so that short pair of crimp tails squeezebare wire strands, while long pair folds over insulation orseal material.

7. Squeeze handle of crimp tool until tightly closed. Toolautomatically opens when the crimping sequence iscomplete.

8. Table B-1. Determine the correct dye or nest for the insu-lation/seal crimp.

9. Lay the back of the insulation/seal crimp tails on theappropriate nest. Be sure the insulation/seal crimp tailsare pointing towards the forming jaws.

10. Squeeze handle of crimp tool until tightly closed. Toolautomatically opens when the crimping sequence iscomplete.

11. See Figure B-16. Inspect the quality of the core (3) andinsulation/seal (2) crimps. Distortion should be minimal.

Figure B-15. Packard Terminal Crimp Tools

Table B-1. Packard Terminal Crimp Tools

SPECIFICATION PACKARD 115 PACKARD 271

Part No. HD-38125-8 HD-38125-7

Type of CrimpNon-sealed terminals,

butt splices

Non-sealed terminals

Dye/nests F-G A-E

Figure B-16. Inspect Core and Insulation/Seal Crimps

Tool tip

Packard 115 Packard 271

d0259x8x

d0260x8x

1. Insulation2. Insulation crimp3. Core crimp

1 23


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ELECTRICAL CONNECTORS B.4

GENERAL

The following table provides a brief description of the connec-tors found on the Firebolt XB9R.

Connector numbers are listed in [brackets] in this manual.

Table B-2. Electrical Connector and Location Table

CONNECTOR COMPONENT(S) DESCRIPTION LOCATION

[5] main fuse spade terminals under seat

[7] tail lamp harness 8-place Multilock left side under tail section

[10] ECM (black) 12-place Deutsch in fairing

[11] ECM (gray) 12-place Deutsch in fairing

[14] cam position sensor 3-place Deutsch under sprocket cover

[18] right rear turn signal 2 1-place bullet under tail section

[19] left rear turn signal 2 1-place bullet under tail section

[22] right hand controls 4-place Multilock beneath right side of fairing

[24] left hand controls 4-place Multilock beneath left side of fairing

[30] flasher 5-place Amp in fairing

[31] right front turn signal 2 1-place bullet beneath right side of fairing

[31] left front turn signal 2 1-place bullet beneath left side of fairing

[33] ignition switch 4-place Augat beneath right side of fairing

[38] headlamp connector 4-place Amp beneath fairing

[39] instrument module 20-place Multilock in fairing

[46] stator 4-place Deutsch under sprocket cover

[61] fuse and diode assembly spade terminals right side of fairing

[62] relay assembly spade terminals left side of fairing

[65] vehicle speed sensor 3-place Deutsch under sprocket cover

[77] voltage regulator 2-place Packard under sprocket cover

[83] ignition coil 3-place Packard beneath airbox base

[84] front fuel injector 2-place Packard underneath airbox base

[85] rear fuel injector 2-place Packard underneath airbox base

[86] fuel pump 4-place Multilock left side of rear shock absorber

[88] throttle position sensor 3-place Packard right side of engine between cylinders

[89] intake air temperature sensor 2-place Amp in airbox base

[90] engine temperature sensor 1-place bullet beneath airbox base

[91A] data link 4-place Deutsch beneath left side fairing

[93] tail light

2-place spade

1-place spade (ground)

back of tail light


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[95] clutch switch 2-place Multilock beneath fairing

[97] cooling fan 2-place Multilock behind rear cylinder

[120] oil pressure switch post terminal crankcase above oil filter

[121] front brake switch 2-place Multilock beneath fairing

[121] rear brake switch 2-place Multilock under seat

[122] horn spade terminals in fairing

[128] starter solenoid spade terminals top of starter

[131] neutral switch 1-place bullet under sprocket cover

[134] bank angle sensor 6-place Sumitomo in fairing

[137] oxygen sensor 1-place Packard behind rear cylinder head

Table B-2. Electrical Connector and Location Table

CONNECTOR COMPONENT(S) DESCRIPTION LOCATION


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INDEX TO WIRING DIAGRAMS B.5

Table B-3. Wiring Diagrams

DIAGRAM PAGE

Main harness B-17

Engine management circuit B-18

Lighting circuit B-19

Horn and instruments circuit B-20

Starting circuit B-21

Starting and charging circuits B-22

Component circuits B-23

2004 Buell Firebolt: Electrical B-17

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2004 XB Firebolt Main Harness

MTR

LOWFUEL

SENSOR

1 1

11

A=

B=

MALE

FEMALE

1 1

1 1

HORN

SPEEDOMETER

[39B]

[39A]

RELAY CENTER

[62B]

LH TURN SIGNAL[31B]

BANK ANGLE SENSOR

CLUTCH SW

[134B]

[95B]

LH CONTROLS

[120A]

[120B]

[38A]

[91A]

[24A]

DATA LINK

HEADLAMP

OIL PRESSURE SW

CMP

VOLTAGE REGULATOR

VSS

NEUTRAL SW

FUEL PUMP

[14B] [14A]

[77B]

[65B] [65A]

[86B][86A]

[131B] [131A]

[7A]

TAIL HARNESS

FOOT BRAKE SWFUSE & DIODE ASSY[61B]

[5A]

[165A]

GROUNDBATTERY

COOLING FAN

STARTERSOLENOID

[121A] [121B]

J-FUSE ASSY

CONTROL SUB HARNESSACTIVE MUFFLER

[GRD2]

[97B]

[128B]

[128A]

[97A]

ENGINE TEMP SENSOR

OXYGEN SENSOR[137B] [137A]

[90B] [90A]

[83B] [83A]

COILIGN.

THROTTLE

SENSORPOSITION

[88A][88B]

IAT

[89B]

[GRD1]

[GRD3]

REAR INJECTOR

[85B]

FRONT INJECTOR

[84B]

[33B]

IGNSWRH CONTROLS

[22A]

DYNOLOOP

[33A]

[31B]

RH TURN SIGNAL

[121B]

BRAKE SW

FLASHER

[30B]

ECM

(GY)

(BK)

[11B]

[164B]

[10B]

[122A] [122B]

2

9

23

24

22

20

19

12

11

10

8DIODE

KEY SWITCH

LIGHTS

ECM

SPARE

SPARE

ACCESSORY

IGNITION

COOLING FAN

BRAKE/HORN/MUFFLER3

17

18

16

14

13 BK

BK

BK

BK

6

5

4

1

1

1

1 R/W

PK

R

GY

V/BN O/W BK

BK/R

W/B

KW

/BK

GY/

O

RR

/GY

R/B

K R

LOC

K

W/YGY

GN

/GY

OBNVV/BN

Y/BK

WBE

BKTN/L

T.G

N

WY/R

PKBKO/W

GN

/YBK

/YWBNVTN

/Y

BKBK

BK/W

R/WV/Y

BN

BKR/YO

BK

BK

RR

R/BK

R

R/GY

GY/O

R

OO

TN/YTN/Y

BK/WLT.GN/Y

BE/OGY

Y/BE

PK/Y

V/GY GY

Y/BN YBK/O BK

BK

BK

GN

RR/Y

TN/V

OW

R/Y R/YO O

BNO/W

VR/Y

Y/R Y/RBK BK

BN/Y BN/YGY GY

TN/Y

R/W RW W

BK/W BK

R/W R/WGN/W GN/WBK/W BK/W

RBK

BKBE

WO/W

GYV/R

BKLT.GN/R

R/WLT.GN/GY

BK/W

V

R/BK

RBKR/BKR/BKGNR/BKR/BKTN/LT.GNBK/R

GYGY/OGY/OBKW/BK

R

BEBEY

O/W

R/BK

Y/BN

R/BK

TN/LT.GN

GN/Y

GN/Y

W/BK

Y/BKBK

BKLT.GN/GYTN/VGN/GYBE/OY/BE

Y/BE

W/YBK/YBN/YBKGY

W

V/RLT.GN/RLT.GN/YPK/YWBK/WBK/OYV/GYGN/WV/Y

VEHICLE SPEED SENSOR

INJECTOR REAR OUTPUT

5V SENSOR POWER

0

BDCA

0 0

+

1

R

1

+

USER + USER +

1

R/BK R/GY

BATTERY BATTERY

1

R

0 0

0PARK

KEY POSITION

IGNITION SWITCH WIRING DIAGRAM

CONNECTING

WIRE SECT mm

WIRE COLOR

ON

OFF

LOCK

SWITCHED IGNITION

THROTTLE POS SENSOR

SYSTEM GROUND A

CAMSHAFT POS SENSOR

FUEL PUMP OUTPUT

OXYGEN SENSOR

CHECK ENGINE LAMP

KEEP ALIVE

INJECTOR FRONT OUTPUT

FAN CONTROL

FRONT COIL PRIMARY

SENSOR GROUND

REAR COIL PRIMARY

SERIAL DATA TRANSMIT

ACTIVE MUFFLER CONTROL

TACHOMETER OUTPUT

SERIAL DATA RECEIVE

SYSTEM GROUND B

AIR TEMP INPUT

BANK ANGLE SENSOR

ENGINE TEMP INPUT

ACTIVE MUFFLER FEEDBACK

1

VSS

INLF

WTA

CH

ING

RO

UN

DIG

NIT

ION

OIL

PR

ES

SU

RE

CH

EC

K E

NG

INE

HIG

H B

EAM

RIG

HT

TUR

NLE

FT T

UR

NN

EUTR

ALBA

TTER

Y

10

2

2

2

5

3

3

3

5

5

5

4

4

4

2

2

2

1

1

1

3

3

3

3IGN

ITIO

NKE

Y SW

STAR

T4

4

4

4

5

5

5

7

6

6

6

8

15

7

7

7

6

13

8

8

8

9

14

9

9

9

2

10

10

10

19

12

12

12 2019181716151413

11

11

11

11

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

123456

1 2 3 4 5

1

1

A A

AA

1

11

2

2

B B

BB

2

22

IGN

3

3

C C

CC

3

33

4

4

D D

4

44

AA

1 122

BB

2 233

CC

3 3

11

1

1

1

1 1

1

1

2

1 1

1

1

1

1 1

11

2

22

2 2

21

3

2 2

2

2

2

2 2

22

bd0024xx

7


HOME

2004 XB Firebolt Engine Management Circuit

MTR

LOWFUEL

SENSOR

1

1

1 1

RELAY CENTER

[62B]

BANK ANGLE SENSOR

CLUTCH SW

[134B]

[95B]

[38A]

[91A]

DATA LINK

HEADLAMP CMP

VSS

NEUTRAL SW

FUEL PUMP

[14B] [14A]

[65B] [65A]

[86B][86A]

[131B]

FUSE & DIODE ASSY [61B]

[5A]

COOLING FAN

J-FUSE ASSY

[GRD2]

[97B] [97A]

OXYGEN SENSOR[137B] [137A]

[83B] [83A]

COILIGN.

IAT

[89B]

[GRD1]

[GRD3]

REAR INJECTOR

[85B]

FRONT INJECTOR

[84B][33B]

IGNSW

RH CONTROLS

[22A]

DYNOLOOP

[33A]

2

24

22

11

10

9

8

18

16

5

4

3

1

1

1 R/W

R

GY

W/B

KW

/BK

GY/

O

R

R/B

K R

LOC

K

W/YGY

GN

/GY

BKTN/L

T.G

N

WBKTN/Y

BK/Y

BKBK

RR

R

GY/O

R

TN/YTN/Y

BK/WLT.GN/Y

BE/OGY

Y/BE

PK/Y

V/GY GY

Y/BN YBK/O BK

BK

RR/Y

BK BKBN/Y BN/Y

GY GY

TN/Y

R/W RW W

BK/W BK

R/W R/WGN/W GN/WBK/W BK/W

BK

GYV/R

BKLT.GN/R

R/WLT.GN/GY

BK/W

R/BK

RBK

R/BK

GYGY/OGY/OBKW/BK

R

Y

R/BK

Y/BN

TN/LT.GN

W/BK

BKLT.GN/GY

GN/GYBE/OY/BE

Y/BE

W/YBK/YBN/YBKGY

V/RLT.GN/RLT.GN/YPK/YWBK/WBK/OYV/GYGN/WV/Y

2

2

5

3

3

5

5

4

4

2

2

1

1

3

3

3

IGN

ITIO

NKE

Y SW

4

4

4

5

5

6

6

15

7

7

13

8

8

9

14

9

9

10

10

19

12

12

11

11

11

123456 1

1

AA

1

11

2

2

BB

2

22

IGN

3

3

CC

3

33

4

4

DD

4

44

AA

AA

1 1

BB

BB

2 2

CC

CC

3 3

1

1

1 1

1

1

1

2

2

2 2

2

2

2

DIODE

COOLING FAN

BRAKE/HORN/MUFFLER

IGNITION

ECM

KEY SWITCH

1[90A]

ENGINE TEMP SENSOR

[90B]

[131A]

1

1 W

TN/V

O

[165A] [165B]

ACTIVE MUFFLER SUB HARNESS

TN/V

OW 2

1

3

ECM

SENSORPOSITION

THROTTLE[88B] [88A]

321 1

23 R/W

V/YBK/W

[161A]

GROUND

V batMUFFLER VALVEACTUATOR

MOTOR

SENSORPOSITION

DC

CO

NTR

OL

ELE

CTR

ON

ICS O

TN/VWBK

11

443322

[161B]

HA

LL S

EN

SO

R

CO

NTR

OL

SIG

NA

L

TN/VWO

3

12

R/BK

R/BK

0

BDCA

0 0

+

1

R

1

+

USER + USER +

1

R/BK R/GY

BATTERY BATTERY

1

R

0 0

0PARK

KEY POSITION


CONNECTING

WIRE SECT mm

WIRE COLOR

ON

OFF

LOCK

TACHOMETER OUTPUTSYSTEM GROUND B

BANK ANGLE SENSORACTIVE MUFFLER FEEDBACK

INJECTOR REAR OUTPUTREAR COIL PRIMARY

FRONT COIL PRIMARYINJECTOR FRONT OUTPUT

CHECK ENGINE LAMPFUEL PUMP OUTPUTSYSTEM GROUND A

SWITCHED IGNITION

ACTIVE MUFFLER CONTROL

SERIAL DATA TRANSMITSERIAL DATA RECEIVE

AIR TEMP INPUTENGINE TEMP INPUT

VEHICLE SPEED SENSORSENSOR GROUND

FAN CONTROLKEEP ALIVE

OXYGEN SENSORCAMSHAFT POS SENSORTHROTTLE POS SENSOR

5V SENSOR POWER

[11B](GY)

[164B]

(BK)[10B]

SPEEDOMETER

[39A]

1

VSS

INLF

WTA

CH

ING

RO

UN

DIG

NIT

ION

OIL

PR

ES

SU

RE

CH

EC

K E

NG

INE

HIG

H B

EAM

RIG

HT

TUR

NLE

FT T

UR

NN

EUTR

ALBA

TTER

Y

2 3 4 5 6 7 8 9 10 12 201918171615141311

[39B]

FEMALE

MALE

B=

A=

bd0022xx


HOME

2004 XB Firebolt Lighting Circuit

RELAY CENTER

[62B]

LH TURN SIGNAL

[31B]

LH CONTROLS

[38A]

[24A]HEADLAMP

[7A]

TAIL HARNESS

FOOT BRAKE SWFUSE & DIODE ASSY

[61B]

[5A]

[121A] [121B]

J-FUSE ASSY

[GRD2]

[GRD3]

[33B]

IGNSW [33A]

[31B]

RH TURN SIGNAL

[121B]

BRAKE SW

FLASHER

[30B]

9

23

24

12

3

17

18

6

R

V/BN O/W BK

RR

/GY R

LOC

K

OBNVV/BN

WBE

BKO/W

WBNV

BK

BN

BKR/YO

BK

BK

RR

R/BK

R/GY

O

BK

RR/Y

R/Y R/YO O

BNO/W

VR/Y

BKBE

WO/W

V

R/BK

R/BK

R

BEBE

O/W

R/BK

10

3

3

5

5

4

4

2

2

1

1

KEY

SWST

ART

78

15

6

1314

2

1911

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

1 2 3 4 5

1

11

2

22

IGN

3

33

4

44

1

1 1

1

1 1

2

2 2

2

22

BRAKE/HORN/MUFFLER

ACCESSORY

LIGHTS

KEY SWITCH

0

BDCA

0 0

+

1

R

1

+

USER + USER +

1

R/BK R/GY

BATTERY BATTERY

1

R

0 0

0PARK

KEY POSITION


CONNECTING

WIRE SECT mm

WIRE COLOR

ON

OFF

LOCK

SPEEDOMETER

[39A]

1

VSS

INLF

WTA

CH

ING

RO

UN

DIG

NIT

ION

OIL

PR

ES

SU

RE

CH

EC

K E

NG

INE

HIG

H B

EAM

RIG

HT

TUR

NLE

FT T

UR

NN

EUTR

ALBA

TTER

Y

2 3 4 5 6 7 8 9 10 12 201918171615141311

[39B]

bd0021xx


HOME

2004 XB Firebolt Horn & Instruments Circuit

MTR

LOWFUEL

SENSOR

1

11

HORN

LH CONTROLS

[120A]

[120B]

[24A]

OIL PRESSURE SW

VSS

NEUTRAL SW

FUEL PUMP

[65B] [65A]

[86B][86A]

[131B]


[5A]

J-FUSE ASSY

[GRD2]

[GRD1]

[GRD3]

[33B]

IGNSW

[33A]

ECM

[122A] [122B]

2

24

12

9

8

18

6

3

1

1

PK

R

RR

/GY R

LOC

K

OY/BK

WY/R

PKBKO/W

GN

/Y

TN/Y

BKBK

RR

R/GY

TN/Y

R/BKO

TN/Y

BK

RR/Y

Y/R Y/RBK BK

GY GY

TN/Y

R/W RW W

BK/W BK

R

O/W

TN/LT.GN

GN/Y

GN/Y

Y/BKBK

BK

BKGY

WBK/W

R/W

2

2

3

3

4

4

5

5

6

6

7

7

8

8

9

9

10

10

12

12

11

11

1 2 3 4 5 6 7 8

AA

11

BB

22

IGN

CC

33

DD

44

AABBCC

1

11

2

22

STAR

T

12453 7

862

10

KEY

SW

12453

15

1119

1314

TN/LT.GN

R/BK

[62B]

RELAY CENTER

DIODE

BRAKE/HORN/MUFFLER

ACCESSORY

KEY SWITCH

[131A]

1

0

BDCA

0 0

+

1

R

1

+

USER + USER +

1

R/BK R/GY

BATTERY BATTERY

1

R

0 0

0PARK

KEY POSITION


CONNECTING

WIRE SECT mm

WIRE COLOR

ON

OFF

LOCK

TACHOMETER OUTPUTSYSTEM GROUND B

BANK ANGLE SENSORACTIVE MUFFLER FEEDBACK

INJECTOR REAR OUTPUTREAR COIL PRIMARY

FRONT COIL PRIMARYINJECTOR FRONT OUTPUT

CHECK ENGINE LAMPFUEL PUMP OUTPUTSYSTEM GROUND A

SWITCHED IGNITION

SERIAL DATA TRANSMITSERIAL DATA RECEIVE

AIR TEMP INPUTENGINE TEMP INPUT

VEHICLE SPEED SENSORSENSOR GROUND

FAN CONTROLKEEP ALIVE

OXYGEN SENSORCAMSHAFT POS SENSORTHROTTLE POS SENSOR

5V SENSOR POWER

[11B](GY)

(BK)[10B]

SPEEDOMETER

[39A]

1

VSS

INLF

WTA

CH

ING

RO

UN

DIG

NIT

ION

OIL

PR

ES

SU

RE

CH

EC

K E

NG

INE

HIG

H B

EAM

RIG

HT

TUR

NLE

FT T

UR

NN

EUTR

ALBA

TTER

Y

2 3 4 5 6 7 8 9 10 12 201918171615141311

[39B]

FEMALE

MALE

B=

A=

bd0020ax


HOME

2004 XB Firebolt Starting Circuit

1

A=

B=

RELAY CENTER

[62B]

CLUTCH SW

[95B]

NEUTRAL SW

[131B]


[5A]

GROUND

STARTERSOLENOID

J-FUSE ASSY

[GRD2]

[128B]

[128A][33B]

IGNSW

RH CONTROLS

[22A]

[33A]

2

24

11

8

18

5

1

BK/R

W/B

KW

/BK

GY/

O

R

R/B

K R

LOC

K

BKTN/L

T.G

N

R

GY/O

TN/Y

BK

BK

GN

RR/Y

TN/Y

R/BK

RBK

R/BKGN

R/BKTN/LT.GNBK/R

GY/OGY/OBKW/BK

R

R/BK

TN/LT.GN

W/BK

10

5

3

3

3

5

5

5

4

4

4

2

2

2

1

1

1

3IGN

ITIO

NKE

Y SW

STAR

T

4

78

15

6

13

9

14

2

1911

1

11

2

22

IGN

3

33

4

44

1

1

1

2

2

DIODE

IGNITION

KEY SWITCH

[131A]

1

MALE

FEMALE

0

BDCA

0 0

+

1

R

1

+

USER + USER +

1

R/BK R/GY

BATTERY BATTERY

1

R

0 0

0PARK

KEY POSITION


CONNECTING

WIRE SECT mm

WIRE COLOR

ON

OFF

LOCK

bd0023xx


HOME

2004 XB Firebolt Starting & Charging Circuit

BATTERY CABLE

SOLENOIDSTARTER

MOTOR

[128A]

A=

B=

[46B][46A]

(HD 3-PHASE)

STATOR

REGULATORVOLTAGE

[77A][77B]

TO VOLTAGE REGULATOR

30A MAXIFUSE

TO J-FUSE ASSY

[5A]

[GRD2]

STARTER

BATTERY

BK

2

11

443322

2

11

R

BK

2

1

R

R/Y

BK

MALE

FEMALE

bd0018xx


HOME

2004 XB Firebolt Component Circuits

MAIN HARNESS

MAIN HARNESS

TO MAIN HARNESS

SUB-HARNESS(ES)

[38LA]

[38HA]

[29B][29A]

HEADLIGHT

FRONT TURN SIGNALS

MTR

LOWFUEL

SENSOR

O BK

TN/VW

GYBKO

/WV/

BN

GN

/GYGY

W/Y

O

TN/VW

R/Y

R/Y

BK

BKBK

BK

BKBK

BN

BNBN

O/W

O/W

V

VV

BK

BK

21R/Y

R

RBK 1

2 21

1234 4

321

Y/R

GYBN/YBK

GN/Y

PK/Y

LT.G

N/Y

LT.GN/GYR/W

BK/W

BK/W

GN/Y

GY

Y/BK

OBNV

BE/W

BK

4

4 4

8 8

1

1

1

11

1

1

BEAMSHI AND LOH3-55W

1

1

A

1

1 432

321

22

11

11

2211

22

11

1

1 2

1

1 432

1

8765432

DCBA

1

111

1

54321

42

A

BKWR

222

66554433

BC

AA A

1

3

1

1

1

1

21

5 5

2

2

2

22

2

2

2

2

BBB B

2

4

2

2

2

2

6 6

3

3 3

7 7

W/BK

WY/BK

Y/BK

W/BK

BE

W

BK

BK

BK

O/W

(HDI ONLY)LAMPS

POSITION O/W

BKW

BKY

BN

BK

BE

BK

BK/R

Y

O/W

Y

BK

V

BK

BE

[86B]

REAR INJECTOR

OIL PRESSURE SWITCH

MUFFLER ACTUATORSUB-HARNESS

Y0206.1AA

TO MAIN HARNESS

POSITIONSENSOR MTR

CONTROL ELECTRONICS

MUFFLER VALVE ACTUATOR

TAIL LAMP/REAR TURNING LIGHTS

RH TURN SIGNAL

TAIL LIGHT

[93A] [93B]

[19A] [19B]

[7B]

[18A] [18B]

LH TURN SIGNAL

TO MAIN HARNESS

YH350.02A8

STATOR

REGULATORVOLTAGE

[128A]

BATTERY CABLE

SOLENOIDSTARTER

BATTERY

MOTORSTARTER

[GRD2]

[5A]

TO J-FUSE ASSY

30A MAXIFUSE

[77A]

[46A]

[165B]

[46B]

[161B]

[161A]

[77B]

TO VOLTAGE REGULATOR

(HD 3-PHASE)

FUEL PUMP

ENGINE TEMP SENSOR

VEHICLE SPEED SENSOR

INTAKE AIR TEMPBANK ANGLE SENSOR

UP

FRONT INJECTOR

FLASHER

[84A]

[30A]

[85A]

[120A]

[65A]

[90A]

[89A]

[134A]

[84B]

[30B]

[85B]

[120B]

[90B]

[89B]

[134B]

RH CONTROLS

BRAKE SW.

CLUTCH SW.

LH CONTROLS

HORN

[22B]

[24B]

[31B]

[31B]

RH TURN SIGNALS

LH TURN SIGNALS

[122B]

[24A]

[31A]

[31A]

[121A]

[95A]

FEMALE

MALE

B=

A=

bd0019xx

REMOVING SOCKET/PIN TERMINALS INSTALLING ...mael.rivoal.free.fr/Manuel Buell XB9R/sm_appb1.pdf2004 Buell Firebolt: Appendix B B-1 HOME 73 AMP MULTILOCK ELECTRICAL CONNECTORS B.1 REMOVING

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