Horn upgrade wiring
 

I just purchased the horn upgrade from our host, and can't figure out how the wiring connectors go together. It did not come with instructions, so I thought I would ask on this message board before I gave them a phone call. I'm hoping somebody who has done this procedure can give me an easy explanation. Thanks!http://forums.pelicanparts.com/uploa...1387135862.jpg

Just a guess, but... try cutting the old connectors off of the horn wires. Crimp on the new terminals (don't forget the yellow bits), insert them into the new plugs and plug them into the horns.

Push the horn button to test the honking.

JR

Javadog...No way do the yellow things fit over the new terminals. Thanks for your idea, however.

Put said yellow things on wires before crimping on metal ends!

I would clip the old plug off slip the yellow seal over the wire strip insulation then crimp end on and push into socket

The yellow things are seals to avoid water entering the contacts. It is a very tight fit.

In this order:

wire, yellow boot, terminal, plug, horn.

JR

Has anyone actually figured out how to get the yellow seals on the multi-strand wire?

I read this post and still have no Idea were they go and how. They have a miniscule hole in them.

A picture would be helpful.

I did a search and found the assembly instructions from the manufacturer. Turns out the little yellow seal is designed for a 0.9-1.4mm wire. Very small! The stock wire in the SC is ~3mm in diameter. And the hole that the seal fits into is 3.45mm in diameter. Math says stock 3mm wires do not fit the connectors. And 1mm wire looks too skinny.

Fortunately an intermediate wire size (1.8mm) will work. My solution to go between the 1.8mm to 3mm wire was to wire the plug with spade connections, so I could retain the factory connector. I am backwards compatible to original horns if so desired in the future.

Wire Sizes:
http://forums.pelicanparts.com/uploa...1395599376.jpg

Building the Plug:
http://forums.pelicanparts.com/uploa...1395599408.jpg

Installed:
http://forums.pelicanparts.com/uploa...1395599430.jpg


Hope this helps the next person.