Evinrude E-TEC 200, Service Manual

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122
ELECTRICAL AND IGNITION
CONNECTOR SERVICING
CONNECTOR
SERVICING
DEUTSCH Connectors
IMPORTANT:
Electrical Grease is recom-
mended. Incorrect grease application can cause
electrical or warning system problems.
To disconnect the connector, press the latch and
pull the connectors apart.
To connect the connector, confirm that the seal is
in place. Clean off any old grease and dirt from
connectors. Apply a light coat of
Electrical Grease
to seal only. Push connectors together until
latched.
Terminal Removal
Use hook-end of Connector Service Tool,
P/N 342667, to pull out wedge from receptacle, or
use other end of tool to pry out wedge from plug.
Use needle-nose pliers to remove wedge from
3-pin receptacle.
Release terminal latch and gently pull on wire.
Terminal Installation
Push terminal through seal until it locks into place.
Fill connector with
Electrical Grease to 1/32 in.
(0.8 mm) below ledge or end of plug.
Push wedge in until latched. Wedge in 2-pin
receptacle is not symmetrical; position latch shoul-
ders next to terminals.
Crimping Terminals
Strip insulation back 3/16 in. (5 mm). Place termi-
nal in 18-gauge notch of Crimping Pliers,
P/N 322696. Position end of wire strands in termi-
nal past wire crimp area, and position end of insu-
lation past insulation crimp area. Capture all wire
strands in crimp; leave no loose strands. Crimp
wire securely. Do not solder. Crimp insulation in
14/16-gauge notch of crimping pliers.
1. Latch
2. Seal
42079A
1. Wedge 42327
2
1
1
1. Terminal latch (receptacle)
2. Terminal latch (plug)
423293
1. Ledge of plug
2. End of plug
42330
1. End of wire strands
2. Insulation crimp area
3. End of insulation
4. Wire crimp area
DRC6205
2
1
2
1
1
4
2
3