You can use these instructions either for my Kit, available here, or for your own parts.
The cable needed is 8 conductor or greater with a shield over all wires, shielded CAT-5 works fine.
The connectors needed are 9-pin miniature plugs.


Instructions for Assembly

Applies to TS-520, TS-820, TS-520S, TS-820S, VFO-520, VFO-820

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.

Pin 1 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 2.

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 other end!

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 each end.

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

Photo 4  - Leads soldered to pins.

Diagram 5 - Pinout, viewed facing long pins.


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