Installation
Butt splicing may be a necessary procedure for the replacement of some components.
1. Strip 3/8 in. (9.5 mm) of insulation off the ends of the wires.
2. Compress the handles of the Packard Crimp Tool (HD-38125-8) until the ratchet automatically opens.
3. See Table B-1. Since the size of the connectors varies with the gauge of the wire, always used the correct components when creating sealed splices.
4. See Figure B-18. Determine the correct dye or nest for the crimping operation. Match the color or gauge wire marked on the butt splice connector with the corresponding crimp cavity on the crimp tool.
![](https://motoinstruction.ru/img/harley/2/111563.jpg)
Figure B-18. Packard crimp tool (Part No. HD-38125-8)
5. Gently apply pressure to the handles until the crimper lightly secures one side of the metal insert inside the butt splice connector. The connector must be crimped in two stages; one side then the other.
6. See Figure B-19. Feed the wire into the butt splice connector until the stripped end contacts the wire stop inside the metal insert.
![](https://motoinstruction.ru/img/harley/2/111564.jpg)
Figure B-19. Installing sealed butt splice connectors
7. Squeeze the handles of the crimp tool until tightly closed. The tool automatically opens when the crimping sequence is complete.
8. Repeat steps 5, 6, and 7 on the other side of the butt splice connector.
Note. If adjacent wires are being spliced, stagger the splices so that the butt splice connectors are spaced at different positions along the length of the wires.
Warning! Use caution when operating the UltraTorch UT-100 or any other radiant heating device. Read the manufacturers instructions carefully before use. Always keep hands away from tool tip area and heat shrink attachment. Avoid directing the heat toward any fuel system component. Extreme heat can cause fuel ignition or explosion. Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed. Be sure to turn the "ON/OFF" switch to the "OFF" position after use. Improper handling could result in death or serious injury.
9. Using the UltraTorch UT-100 (Part No. HD-39969), Robinair Heat Gun (Part No. HD-25070) with heat shrink attachment (Part No. HD-41183) or other suitable radiant heating device, heat the crimped splice to encapsulate the butt splice connection. Apply heat from the center of the crimp out to each end until the meltable sealant exudes out both ends of the connector.
Note. It is acceptable for the splice to rest against the heat shrink tool attachment.
10. Heat the center of the splice until the crimp indentations disappear and the tubing assumes a smooth cylindrical appearance.
Table B-1. Common sealed splices
GAUGE WIRE | CONNECTOR COLOR | PART NO. |
18-20 | Red | 70585-93 |
14-16 | Blue | 70586-93 |
10-12 | Yellow | 70587-93 |