Buell XB 2010, Service Manual

Page: 575 / 714

2. See Figure A-4 and Figure A-5 . Select the pin/socket ter-
minals from the parts catalog and identify the insulation
crimp tails (1) and the wire 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. Refer to
Table A-1 .
Table A-1. AMP Multilock Connector: Crimp Tool Wire
Gauge/Nest
NEST WIRE GAUGE
Front 20
Middle 16
Rear 18
2
3
1
sm00004
1. Insulation crimp tail
2. Wire crimp tail
3. Locking bar groove
Figure A-4. AMP Multilock Connector: Pin Terminal
2
3
1
sm00001
1. Insulation crimp tail
2. Wire crimp tail
3. Locking bar groove
Figure A-5. AMP Multilock Connector: Socket Terminal
Crimping 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 A-6 . Squeeze the handles to cycle the AMP
MULTILOCK CRIMPER (Part No. HD-41609) to the fully
open position (1).
2. Raise locking bar by pushing up on bottom flange (2).
NOTE
See Figure A-4 and Figure A-5 . Hold the terminal with the
insulation crimp tail (1) facing up. The tool will hold the terminal
by the locking bar groove (3) and crimp the wire crimp tail (2)
around the bare wire of the stripped lead and the insulation
crimp tail around the insulation.
3. See Figure A-6 . With the insulation 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.
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 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. Tool
automatically opens when the crimping sequence is com-
plete.
8. Raise up locking bar (7) and remove crimped terminal.
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2010 XB Service: Appendix A Connector Repair A-3