1. COMMON MODEL INFORMATION 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. 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.
AWG Wire Size Range Slot Sizes -74k==- STOPS 1.25 Small wire (1 8-20) 2.0 I Large wire (14-16) I Squeeze the tool with both hands until the stops make contact. Crimping the Insulation Crimp Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. 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.
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. 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.