Buell 2005 P3, Service Manual, Page: 19 / 426

Appendix B: Wiring B-3
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CRIMPING INSTRUCTIONS
1. See Figure B-3. Squeeze the handles to cycle the
DEUTSCH TERMINAL CRIMP TOOL (Part No. HD-
39965) 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 0.1562 in. (4.0 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.
NOTE
Inspect the quality of the core and insulation crimps. Distor-
tion should be minimal.
Figure B-2. 3-pin Locking Wedge Orientation
a0267x7x
Socket
housing
Pin housing
Arrow points to
external latch.
Figure B-3. Deutsch Crimping Procedure
1. Insert contact through middle
hole of locking bar. 2. Insert stripped lead until it
contacts locking bar. 3. Close and squeeze crimp tool.
4. Raise locking bar and
remove contact. 5. Inspect quality of core and
insulation crimps.
a0268x7x
Locking bar
Insulation crimp
Core crimp