Econoseal plug

[blueyedbiker]

A few observations having just made up the econoseal plugs for the front lights, the indicator repeaters came with bullet connectors so needed changing to econoseal to fit the plug.  I believe the ones supplied by CCC come with the pin already fitted.

• The pins come attached to a strip and need to be snipped off where the pin joins the strip
• The silicone seals are colour coded for different cable thicknesses - green=thin, brown=medium, yellow=thick
• The seal should be slipped over the cable before you trim to expose the core
• The thin crimping "wings" at the back (away from the pin end) are for the silicone seal, the wider "wings are for the cable core
• Only about 3mm of cable core needs to be exposed otherwise it interferes with the pin/plug body locating mechanism
• I bought a Paron JX-1601 crimper kit for about £20, a lot cheaper than the econoseal crimper but works OK
• Hold the core in place, place it into the 4.0 anvil, wings down but with the thin "seal wings" clear and crimp.  it's a tight fit and will trash the 2 very small lugs on the sides but no matter.
• Insert the silicone seal/wings, wings down into the 6.0 anvil and crimp, this should produce a neat job.
• To assemble the plug;
• MAKE SURE THE CABLE ROUTING IS CORRECT AS THE PLUGS ARE DIFFICULT TO TAKE APART!
• Push the pins into the black body of the plug making sure you're using the correct hole. (obviously)
• They will only click into place if they are the correct way round so you might need to rotate 180 degrees.  They lock into place by a small wedge dropping into the void in front of the core crimp which is why you only need a small amount of core.
• If the pins ar not properly clicked into place the yellow plug insert will not fit correctly.
• Push in the yellow insert, it might need a bit of poking with a screwdriver to get the pins to line up and as it locks into place the 2 horizontal blades at the back slide into the gaps between the locking wedges and lock them all in place.

Good luck!

[John Vine]

Very useful guide! 

MAKE SURE THE CABLE ROUTING IS CORRECT AS THE PLUGS ARE DIFFICULT TO TAKE APART!

Although there's a special tool for extracting pins (it lifts the little locking wedge you describe), a thin-bladed jeweller's screwdriver will do the job.  Remove the yellow pin guide, and then insert the screwdriver blade under the pin while at the same time pulling gently on the wire.

JV

[blueyedbiker]

Thanks for the tip John, as you've probably worked out I speak from experience.

[Shortshift]

I think you can even use a paper clip (unwound, of course) to do the job of releasing the pins.  That said, you can buy a set of the special tools that will deal with releasing all sorts of connectors and terminals on eBay for pennies, if I recall correctly.  Handy to have sitting in the 'special tools that are seldom needed but immensely useful when required' place...

James

[anthonym]

Grateful for this post.

What's the difference between Econseal and Superseal and XYZ-Seal? Specifically I am wondering about waterproofness and quality of build. https://www.aliexpress.com/item/ECONOSEAL-AMP-WATERPROOF-

Anthony

[blueyedbiker]

Hi Anthony, can't help you on that one 'm'fraid, I've only used econoseal, no experience of the others.

[Strangely]

I found this guide to be really helpful:

https://www.hidplanet.com/forums/forum/the-hidplanet-university/how-to-diy/51029-how-to-taking-apart-amp-connectors