B-8 2007 Buell Lightning: Appendix B
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CRIMPING INSTRUCTIONS
1. See Figure B-12. Squeeze the handles to cycle the crimp
tool to the fully open position.
2. Raise locking bar by pushing up on bottom flange. With
the crimp tails facing upward and the rounded side of the
contact barrel resting on the concave split level area of
the crimp tool, insert contact (socket/pin) through middle
hole of locking bar.
3. Release locking bar to lock position of contact. If the
crimp tails are slightly out of vertical alignment, the crimp
tool automatically rotates the contact so that the tails
face straight upward. When correctly positioned, the
locking bar fits snugly in the space between the contact
band and the core crimp tails.
4. Strip lead removing 5/32 in. (4 mm) of insulation. Insert
wires between crimp tails until ends make contact with
locking bar. Verify that wire is positioned so that short
pair of crimp tails squeeze bare wire strands, while long
pair folds over insulation material.
5. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
complete. 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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