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Discussion Starter #1
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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Any running problems when you had the wires soldered together ?
 

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Discussion Starter #3
I only had 1 wire soldered and the bike seemed to run OK. But I wanted to fix it right because you never know if a problem would pop up because of the solder repair.
I still needed to upgrade to the 2011 pins anyways because I was just using dielectric grease on the TCA plug to prevent the bike from going into limp mode per HD instructions on TT418A TBW service bulletin.
 
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