Buell 2008 XB SERIES, Electrical Diagnostics Manual, Page: 222 / 288

A.10 SEALED SPLICE CONNECTORS
SEALED SPLICE CONNECTOR REPAIR
TOOL NAME PART NUMBER
ROBINAIR HEAT GUN HD-25070
PACKARD CRIMPING TOOL HD-38125-8
ULTRA-TORCH UT-100 HD-39969
HEAT SHIELD ATTACHMENT HD-41183
General
Splice connectors and several OE ring terminal connectors
use heat shrink covering to seal the connection.
Preparing Wire Leads
NOTE
If adjacent wires are to be spliced, stagger the splices so that
the sealed splice connectors will not touch each other but are
located at different positions along the length of the wires.
1. Using a shop gauge, identify the gauge of the wire.
2. Match the wire gauge to a sealed splice connector by color
and part number. Refer to
Table A-4 .
3. Using a wire stripper, cut and strip a length of insulation
off the wire ends. Refer to
Table A-4 for the strip length.
Table A-4. Sealed Splice Connectors
STRIP LENGTH PART NO. COLOR WIRE GAUGE
3/8 in. (9.5 mm) 70585-93 Red 18-20
(0.5-0.8 mm)
3/8 in. (9.5 mm) 70586-93 Blue 14-16
(1.0-2.0 mm)
3/8 in. (9.5 mm) 70587-93 Yellow 10-12
(3.0-5.0 mm)
NOTE
If any copper wire strands are cut off of the wire core, trim the
end and strip the wire again in a larger gauge stripper.
Splicing Wire Leads
NOTE
See Figure A-25 . The connector is crimped twice - one side
and then the other.
1. See Figure A-24 . Open the PACKARD CRIMPING
TOOL (Part No. HD-38125-8) ratchet by squeezing the
handles closed.
2. Match the connector color to the wire gauge crimp die in
the jaws and insert one end of the sealed connector.
3. Gently squeeze the handles until the connector is held in
the jaws.
4. See Figure A-25 . Feed the stripped end of a wire into the
connector until the wire stops inside the metal insert (1).
5. Squeeze the handles tightly closed to crimp the lead in
the insert (2). The tool automatically opens when the
crimping is complete.
6. Slide the connector to the other half of the metal insert.
Insert the stripped wire lead (1) until it stops, and crimp
the lead in the insert (2).
Be sure to follow manufacturer's instructions when using
the UltraTorch UT-100 or any other radiant heating device.
Failure to follow manufacturer's instructions can cause a
fire, which could result in death or serious injury. (00335a)
• Avoid directing heat toward any fuel system component.
Extreme heat can cause fuel ignition/explosion resulting
in death or serious injury.
• Avoid directing heat toward any electrical system com-
ponent other than the connectors on which heat shrink
work is being performed.
• Always keep hands away from tool tip area and heat shrink
attachment.
7. Use an ULTRA-TORCH UT-100 (Part No. HD-39969), or
a ROBINAIR HEAT GUN (Part No. HD-25070) with a
HEAT SHIELD ATTACHMENT (Part No. HD-41183), to
heat the connector from the center of the crimp (3) out to
each end.
NOTE
It is acceptable for the splice to rest against the heat shrink
tool attachment.
Inspecting Seals
See Figure A-25 . Allow the splice to cool and inspect the seal.
The insulation should appear smooth and cylindrical. Melted
sealant will have extruded out the ends (4) of the insulation.
1
2
3
sm00050
1. Red connector die
2. Blue connector die
3. Yellow connector die
Figure A-24. Packard Crimping Tool (HD-38125-8)
A-20 2008 Buell XB Diagnostics: Appendix A Connector Repair