Connector Servicing - Evinrude E-TEC 200 Service Manual

ELECTRICAL AND IGNITION

CONNECTOR SERVICING

CONNECTOR
SERVICING
DEUTSCH Connectors
IMPORTANT:
Electrical
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.
1
1. Latch
2. Seal
Terminal Removal
Use hook-end of
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.
1. Wedge
122
Grease is recom-
Connector Service
Release terminal latch and gently pull on wire.
1
1. Terminal latch (receptacle)
2. Terminal latch (plug)
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.
2
1
1. Ledge of plug
2. End of plug
42079A
Push wedge in until latched. Wedge in 2-pin
receptacle is not symmetrical; position latch shoul-
ders next to terminals.
Tool,
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
1
14/16-gauge notch of crimping pliers.
2
42327
3
1. End of wire strands
2. Insulation crimp area
3. End of insulation
4. Wire crimp area
2
423293
2
42330
1
4
DRC6205