SeaDoo 3D Manual page 373

Section 13 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS
Pry back the retaining tab while gently pulling wire
back until terminal is removed.
Terminal Crimping
The size of the wires must be 20 to 16 AWG with
a wire insulation diameter having a minimum di-
mension of 1.7 mm (.067 in) and a maximum di-
mension of 2.78 mm (.106 in).
The wire strip length must be 5.1 mm (13/64 in).
NOTE: When stripping wires, ensure conductor is
not nicked, scrapped or cut. Wire stripping tool
jaws may leave marks on the surface of the wire
insulation. If these marks occur at the location
of the wire seal, leakage may result. Insulation
surface within 25 mm (1 in) from the tip of the
terminal must be smooth.
All terminals in AMP connectors must be crimped
using the crimping tool (P/N 529 035 909) and
crimper die (P/N 529 035 908).
CAUTION: If terminals are not crimped using
the proper crimping tool, the wire seal may be
damaged.
smr2005-073
Subsection 01 (ELECTRICAL CONNECTORS)
CRIMPING TOOL
All circuits are sealed by a diaphragm in the rubber
wire seal. When installing a terminal in connector,
the diaphragm is pierced as the terminal passes
through it.
If the diaphragm is pierced and the cavity is not
used, install a seal plug, large end first, into circuit
cavity as far as it will go.
NOTE: It is suggested that all unused circuit cav-
ities be sealed with a seal plug, even if they are
not pierced.
1. Seal plug
2. Wire seal
CAUTION: Do not pierce the diaphragm with
a sharp point when performing electrical trou-
bleshooting. The resulting pinholes in the in-
sulation will allow moisture to penetrate the
system and possibly result in system failure.
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