Re-pinning the Throttle Control Actuator Plug Wires
I had a broken wire on my TCA plug so a repair was in order, I did solder the wire together but I wanted to fix the wires/plug right. Also the TCA pins need to be upgraded to the HD PN72663-11 pins, the upgraded pins are silver plated and the 2008 to 2010 pins are tin which will cause throttle problems causing the bike to go into limp mode. Also the TCA plug housing was in need of replacement because the tab to unlock the tab from the TCA was broken and the rubber seal inside the TCA plug housing was coming apart, I relate these issues with age and heat.
The 72663-11 pins are around $.80 each and I needed 6 pins (I got a few extra pins) and the TCA plug housing was around $13. I also needed a Open Barrel Contact Crimping Tool which I found for $25. I also used a wire stripper and side cutter pliers.
I removed the fuel tank and the top of the wire tray to see if I had any extra slack in the wires, there wasn't much extra slack but there was enough to do the job. I wrote down the wires color and location on the TCA plug housing for reference when installing the pins in the new TCA plug housing.
I then pulled the TCA plug housing apart and cut the existing pins off as close to the pin as possible to save as much wire as I could. I then stripped the insulation off the wires and then crimped the new pins on the wires and installed the wires in the new TCA plug housing.
This is a easy repair to do if you have the right tools and it can be done in 1 hour if you take your time.
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08 FLTR candy red sunglo,with 2015 103 HO, V&H Dresser Duals with Monster Rounds, Power Vision tuner, Willy Shiny Wheels and Forks and a bunch of other stuff.