Check Connector And Terminal

Unless otherwise nothing noted, always check the resistance with ambient temperature at 20°C (68°F). When the inspection was performed at high ambient temperature immediately after the engine was stopped, the resistance value becomes outside the specified value. Therefore, perform the inspection after the engine is cooled down.

1. When disconnecting the connector with lock, push the connector to the engaging side to loosen the lock claw, and then unlock the lock.
2. When disconnecting the connector, do so while holding not Wire harness but the connector.
3. Before connecting the connector, check the terminal for deformation, damage and disconnection.
4. To connect the connector with lock, be sure to insert completely until a click is heard.
5. When checking the connector using an electrical tester, use a mini test lead and perform the inspection from the Wire harness side.

1. With the connector connected, check the insertion condition and lock effectiveness while holding the connector housing. (Mating condition)
2. With the connector disconnected, pull Wire harness lightly for inspection. (Terminal disconnection, terminal crimping condition and core breakage)
3. Visually check for presence of rust, metal pieces and water as well as bends of the terminal. (Corrosion, intrusion of foreign matter, and terminal deformation)
4. Prepare a terminal that is the same as the male terminal, and insert it to the female terminal. Then, check the terminal contact pressure, mating condition and sliding heaviness.
5. When checking the connector using an electrical tester, use a mini test lead and perform the inspection from the Wire harness side.

1. When the connecting portion is soiled, clean there using an airsoft gun, waste cloth and the like. Never ground the connecting portion, because grounding with sandpaper or similar peels off the surface plating on the connecting portion.
2. When the contact pressure is faulty, replace the female terminal. At this time, if the corresponding male terminal on the part side is gold-plated (in gold color), use gold plating for the female terminal, and if tin-plated (in silver color), use tin plating.
3. When there is no fault at the connecting portion, clean there with an airsoft gun, and apply connector grease. (Doing so prevents oxidation and wear of the connecting point.)
4. Prepare a terminal that is the same as the male terminal, and insert it to the female terminal. Then, check the terminal contact pressure, mating condition and sliding heaviness.

1. Anticorrosive grease is applied to the terminals of the connector at locations such as the generator and headlight that are susceptible to water.
2. When the connector grease is insufficient, or the terminal is repaired, apply the connector grease to the female terminal.
   CAUTION:

   • Be sure protect from dust and so on.
   • Do not use a screwdriver or similar tool for the application.
3. Adherence of grease to the O-ring and rubber stopper of the waterproof connector is not a problem. However, adherence to other rubber parts (such as the weather strip and grommet for Wire harness) may cause deterioration and discoloration. If adherence happens, wipe off immediately.
4. Prepare a terminal that is the same as the male terminal, and insert it to the female terminal. Then, check the terminal contact pressure, mating condition and sliding heaviness.

1. When disconnecting Wire harness, check the routing and clamping condition before conducting the work so that reproduction can be performed surely.
2. Do not twist, pull or unnecessarily loosen Wire harness.
3. Do not interfere Wire harness with the location that becomes high temperature, rotation portion, sliding portion, vibrating portion and sharp-edge portion (such as the panel end and screw tip).
4. When installing the parts, do not pinch Wire harness.
5. Do not tear the shield of Wire harness. If tearing happens, replace or surely repair with vinyl tape.