Cycle Terminal

OEM Style Wiring Harness Electrical Connectors and Terminals

Keep checking back for links on How to’s, Wiring Diagrams, and other great information.

If you have any Questions, please feel free to Email me at: Joe@cycleterminal.com

First - Strip you wire to the proper length needed, This may be different for each type of terminal crimped.

This one approximately 5 to 6 mm will need to be striped.

Do not to nick any wire strands like I did in this second picture.

If you do cut the wiring down to the damaged standing, and re-strip the wire.

Next - You will place the terminal in the Crimp tool die. In the photo on the left you are looking at the upper die, the left side of the die in the photo is the wire/conductor crimp. Right side of the die will be the insulation crimp.

Place the terminal in the die, so the wings for the conductor crimp are off set slightly center into the gap between the dies surfaces.

This will give you a needed bell mouth.

So neither the tool die, or terminal cuts into the wire stranding. (See Note Below)

And Finally - Making sure the wire stranding from your striped wire is straight, not spread out/apart, and not twisted. Insert your striped wire into the terminal, making sure all the strands make it into the terminal to be crimped.

(With some terminals, the wire will only go in so far before the insulation bottoms out in the terminal) otherwise if striped to the proper length, make sure you have about 1mm of wire sticking out the opposite side.

You can now crimp the terminal, and should have something like this on the right.

First - Before striping the wire, Insert the wire through the seal.

Then you can strip the wire carefully so you don't nick or cut any of the stranded wires.

Next - You will place the terminal in the Crimp tool die.

Place the terminal in the die, so the wings for the conductor crimp are positioned toward the wire seal just off the die about .5mm.

(As seen in the photo on the right)

This will give you a bell mouth, so the tool or crimped terminal does not cut into the wire stranding.

Make sure the wire stranding from your striped wire is straight, not spread out/apart, and not twisted. Insert your striped wire into the terminal, making sure all the strands make it into the terminal to be crimped.

(I normally slide the seal just up to the bare wire before inserting the wire into the terminal) I did it like this for the photo’s.

You can now crimp the terminal, and then slide the seal into place.

You should have something like this on the right.

And Finally the wire seal - (which serves as insulation stain relief, and to seal out the elements on this the sealed connector system)  

This will only get a partial crimp, with the largest die on this tool.

You want just enough of a crimp to hold the seal in place, You don’t want to cut into it.

So stop applying pressure when you get to this point,

as seen in the photo on the right.

Release the ratchet using the lever at the bottom of the tool frame, you should now have a crimped terminal that looks like the photo on the right.

Good luck, you can do it too!!

Basically the same as above.

This will be a 2 step crimp as well, the Conductor, then the insulator.

Using a standard 250 14-18 AWG terminal and 16 Gauge wire.

Even though this tool is not designed for these terminals you can get some really good crimps with it.

(Provided you use the proper terminal, Wire Size, and tool die)

On the left is a photo of the back side of the terminal, showing the pressure the die put on the terminal.

And this one looks pretty good.

Now you can crimp the insulation with one of the larger dies.

And this should be your results when finished.

Good luck!!

          I hope to get some photo’s of the smaller pin terminals soon!!

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Here is a Proper Terminal crimp!!

14 AWG wire with a  .8mm Thick 6mm ring terminal.

1 -Notice the insulation crimp does not pierce the wire insulation, but holds it nicely. And there is plenty of insulation for it the grab.

2 - The conductor/wire is extended slightly past the wire crimp.

3 - The terminal is not distorted.

4 -  The conductor/wire crimp has a Bell Mouth on the top edge closest to the insulator.

This means that neither the crimp tool, or the terminal cut into the wire stranding of the conductor.

Note: You may get close, But None of these crimp tools are capable of crimping these thick .81 6mm Ring terminals at this Quality.