User Manual

1. COMMON MODEL INFORMATION
1.25
INSTALLING THE NEW TERMINAL
Carefully match the old terminal with the new one
from the Terminal Service Kit. Choose the correct
replacement terminal based on the wire size range
the terminal will accommodate.
If the replacement terminal quantities are low,
reorder by using the terminal part number listed on
the inside lid of the Terminal Service Kit.
Small wire (1 8-20)
AWG Wire Size Range
Slot Sizes
2.0 I Large wire (14-16) I
Depending on the size of the wire you are repairing,
use the proper size slot in the crimping tool.
WIRE CRIMP
Without wire seal
INSULATION
/
CRIMP
End
of seal 1 mm bevond
With wire seal
the insulation crimp
e-
End &wire insulation
Strip the insulation off the end of the wire so the
wire fits in the new terminal as shown. (If the wire
has a wire seal, replace it with a new one from the
kit.)
After stripping the end of the wire, make sure you
did not cut any wire or wire strands. If you did, cut
the wire even with the insulation, and strip
it again.
ANVIL ' TERMINAL
Position the terminal in the crimping tool slot with
the solid portion of the terminal toward the anvil and
the open section toward the former.
Insert the wire into the terminal.
-74k==- STOPS
Squeeze the tool with both hands until the stops
make contact.
Crimping the Insulation Crimp
Without a wire seal: Depending on the wire size,
you June need to use the next larger slot size.
(Example: If you used the 1.25 crimp slot for the
wire crimp, then use the 2.0 crimp slot for the
insulation crimp.) Position the crimping tool over
the insulation crimp section of the terminal, then
squeeze the tool with both hands until the stops
make contact.
With a wire seal: Position the insulation crimp in
the
5.5 crimping slot, then carefully squeeze the
crimp closed until its ends are touching and
making a full circle shape.
1151
Date of Issue: June 2003
0 2001-2003 American Honda Motor Co., Inc.