Instructions for Assembly
Applies to TS-520, TS-820, TS-520S, TS-820S, VFO-520,
New for the CA-9K - While connector supplies last, the kit now
includes the original 9-pin Kenwood-style connectors with cupped solder
connections that will make assembly easier.
Fortunately, all the Kenwood Hybrid remote VFO cables are
wired pin-for-pin. That is, each pin at one end of the cable
connects to the identical pin at the other end of the cable.
connects to Pin 1, Pin 2 connects to Pin 2, etc. The only pin
that has to be closely watched when we assemble the cable is the shield
for the entire cable assembly. The shield must be connected to pin 2
as shown by the description "bare wire" in Diagram 5.
To begin, strip
the insulation from both ends of the supplied cable back 5/8".
This will expose 9 colored wires and the shield wire. Remove any
aluminum shielding foil.
Next, strip 1/2" of insulation from
each of the colored wires, except the Grey wire - Cut this one
off short. It will not be used. This leaves 1/8" of insulation on all the other wires.Leave the bare wire full
length. Next, twist and tin the 1/2" of bare strands on each of the wires - This is important, as assembly is almost impossible if you don't tin these leads. However, it is very easy if you do tin them. See photo 3.
Slide the pin carrier over the prepared cable end as shown in photo 3. Using a soldering iron with a
small tip and perhaps a "third hand" to assist, solder the bare wire
(shield) to pin 2 as shown in Photo 4. There is no
freedom here, the shield must connect to Pin
NOTE: The orientation in Diagram 5
is looking at the "pin end" of the connector, where you are soldering the
wires onto the long pins.
I used standard electronic color coding,
proceeding clockwise around the connector.
Bare Wire (Shield)
The Grey lead is cut off - Unused.
It makes no difference what
color sequence you use, as long as you use the identical sequence at the
Once you have all the leads connected,your carrier
should look something like Photo 4. Do the same on the other end of
the cable, being sure that each colored wire goes to the identical pin on
Lastly, slide the cover over the pins, and secure it to the pin carrier with RTV (clear 100% silicone bathroom caulk). This will allow for disassembly of the connector should a wire ever break.
NOTE: If you're a bit heavy-handed while soldering, an alligator clip can be used as a heat sink on the pin solder joints while you solder each wire to the pin.
Photo 1 - Kit Contents
Photo 2 - Completed cable assembly
Photo 3 - Stripping and tinning the leads
4 - Leads soldered to pins.
Diagram 5 - Pinout, viewed facing long pins.