Buell P3 - Page 22

B-6 Appendix B: Wiring
HOME
TERMINAL CRIMPS
Prepare Wire Leads
1. Strip wire lead removing 0.1562 in. (3/16?) (4.0 mm) of
insulation from the wire lead.
2. See Figure B-4. and Figure B-5. Select the pin/socket
terminals from the parts catalog and identify the wire
crimp tails (1) and the insulation crimp tails (2) and the
groove for the crimp tool locking bar (3).
3. Identify the wire lead gauge and the corresponding
crimper tool and nesting die.
Crimp Terminals to Leads
NOTE
Crimping with an Amp Multilock tool is a one step operation.
One Squeeze crimps both the wire core and the insulation
tails.
1. See Figure B-6. Squeeze the handles to cycle the AMP
MULTI-LOCK CRIMPER (HD-41609) to the fully open
position (1).
2. Raise locking bar by pushing up on bottom flange (2).
NOTE
See Figure B-4. and Figure B-5. Hold the terminal with the
installation crimp tail (1) facing up. The tool will hold the termi-
nal by the locking bar groove (3) and crimp the wire crimp tail
(2) around the bare wire of the stripped lead and the insula-
tion crimp tail around the insulation.
3. See Figure B-6. With the installation crimp tail facing
upward, insert terminal (pin or socket) (3) through the
locking bar, so that the closed side of the terminal rests
on the nest of the crimp tool. Refer to Table 1-2.
4. Release locking bar to lock position of contact (4). When
correctly positioned, the locking bar fits snugly in the
space at the front of the core crimp tails.
5. Insert stripped end of lead (5) until ends make contact
with locking bar.
6. Verify that wire is positioned (6) so that wire crimp tails
squeeze bare wire strands, while insulation crimp tails
fold over the wire lead insulation.
7. Squeeze handle of crimp tool until tightly closed (7). Tool
automatically opens when the crimping sequence is
complete.
8. Raise up locking bar (8) and remove crimped terminal.
Table 1-2. Crimp Tool Wire Gauge/Nest
Wire Gauge Nest
20 Front
16 Middle
18 Rear
Figure B-4. Pin Terminal
Figure B-5. Socket Terminal
2
3
1
f2520x1x
1. Insulation crimp tail
2. Wire crimp tail
3. Locking bar groove
2
3
1
f2519x1x
1. Insulation crimp tail
2. Wire crimp tail
3. Locking bar groove