I have made several full wiring harnesses for motorcycles and ATVs (mostly late 70s and 1980s motorcycles). A lot of it still applies to Blasters so I thought I would make a guide on using Blaster compatible crimp terminals. Everything shown below can be bought from either MikesXS.com or vintageconnections.com . Let me know if anyone finds this guide useful. I can make more harness/wiring related guides.
Below are some of the common connections you may see on a Blaster. We will be crimping the bottom two:
We start out with a ratcheting crimping tool. The dies in this crimper are made just for this style terminal. You can buy it with the dies for around $30-$40
Here are the male and female connections. Each has its own rubber seal.
The far left side of the crimp is for the wire insulation. You want to strip off enough wire so the center crimp will hold it, but not so much that it sticks into the plug itself.
Make sure you install the rubber seal BEFORE you crimp on the terminal.
Put the terminal in the crimper and close it until it holds the terminal for you.
Put the wire into the terminal.
Look into the crimp and make sure you do not push the wire in too far. You want the center crimp to only catch the copper wire and not the insulation.
Compress the crimper until it unlocks. Check out your work.
Repeat the same steps for the female crimp.
All finished:
Below are some of the common connections you may see on a Blaster. We will be crimping the bottom two:
We start out with a ratcheting crimping tool. The dies in this crimper are made just for this style terminal. You can buy it with the dies for around $30-$40
Here are the male and female connections. Each has its own rubber seal.
The far left side of the crimp is for the wire insulation. You want to strip off enough wire so the center crimp will hold it, but not so much that it sticks into the plug itself.
Make sure you install the rubber seal BEFORE you crimp on the terminal.
Put the terminal in the crimper and close it until it holds the terminal for you.
Put the wire into the terminal.
Look into the crimp and make sure you do not push the wire in too far. You want the center crimp to only catch the copper wire and not the insulation.
Compress the crimper until it unlocks. Check out your work.
Repeat the same steps for the female crimp.
All finished:
