Tricks to install electrical pins in connectors

[Randy W.]

Can I get some advice on installing/removing pins in the waterproof connectors on a 1980 200HP Johnson? I purchased a couple of new coils and would like to install with new pins into the original connectors rather than splicing. The original manual I have shows some specialized tools, but I thought someone might have some field knowledge of doing these with some other time of pin extractor/installer type tool/process. Thanks! Randy.

 

[boobie]

Re: Tricks to install electrical pins in connectors

I know the OEM wants quite a few bucks for these but you may want to try CDI Electronics for them. I wish I could help you and I know I've seen some inexpensive ones but can't remember where. You should be able to find the crimpers for them at Radio Shack. I'm sure someone else will chime in here with a good solution.

 

[Randy W.]

Re: Tricks to install electrical pins in connectors

Thanks for the CDI idea...that makes sense. Radio Shack did not have anything comparable, but that was a good idea, too. I'm going to keep trying to locate a cost effective route, being that I may use them only once or twice.

 

[jasper60103]

Re: Tricks to install electrical pins in connectors

I'm not familiar with your engine, but I was able to remove/install those coil connector pins with some needle nose pliers on my '81 25hp. Lubricate the pins with alcohol first. Also, I hear hemostats work well too.

 

[bigrockets]

Re: Tricks to install electrical pins in connectors

You can find pin extractor tool on ebay by the hundreds. Now that we have outsourced all of our electronics work to China there are plenty of surplus tools at bargain prices there. I have used flat shim stock to slide over the pin from the front and compress the tabs. Take a piece of shim stock and roll it into a cylindrical shape that will fit over the pin. Push it into the connector over the pin while gently pulling from the wired end. It will slide out as soon as you compress the tabs. I have also used a metal ballpoint pen refill cut open and cleaned out of ink. The idea is to brush the tabs down so that you can slide the pin out from the back of the connector.

 

[Randy W.]

Re: Tricks to install electrical pins in connectors

You can find pin extractor tool on ebay by the hundreds. Now that we have outsourced all of our electronics work to China there are plenty of surplus tools at bargain prices there. I have used flat shim stock to slide over the pin from the front and compress the tabs. Take a piece of shim stock and roll it into a cylindrical shape that will fit over the pin. Push it into the connector over the pin while gently pulling from the wired end. It will slide out as soon as you compress the tabs. I have also used a metal ballpoint pen refill cut open and cleaned out of ink. The idea is to brush the tabs down so that you can slide the pin out from the back of the connector.

You guys are awesome! Sometimes a procedure in the manuals can appear so complicated, yet there are such easy solutions provided by the years of experience on this forum. Ain't it great!