Topic: New wires for old coils

[martin99]

Hi all
Just posted this in reply to another member's question, and thought it might be of wider interest. Apologies to those of you whom I am teaching to suck eggs and try to see beyond the Yamaha! (no offence, Yam owners!)
http://www.xs11.com/forum/showthread.php?s=0152c5ed8c5557527d305c4e7aa82683&threadid=137

[martin99]

I should have added that I have used this method with success (now a bright blue spark instead of a feeble orange one) on my 750F2. The Honda coils don't have the brass pin (or at least mine didn't) but if you cut back the wire a half inch before it disappears into the bottom of the coil body you have enough to solder your new wire on. I sealed the new wires in with RTV silicon, which is pliable enough when curing to mould it into the correct shape, making for a nigh on invisible repair! It was time consuming I'll admit, but cost a fraction of the price of a new set of coils.

[STLrocker]

i have replaced wires on my 750 coils as well. what i did was a little different.

 i cut the old wores off flush with the end of the coils. then i took a drill bit of the same size as the wires, and drilled into the old wire inside the coil. i drilled in about 3/8 - 1/2". you then have a hole with the end of the wire down inside the middle.

you can then take a pin or brad nail and stick it into the copper wire inside the hole. you will need to push it in part way and leave some sticking out to about the end of the coil.

then take your new wire and stick it into the hole with the pin you inserted going into the copper conductor in the new wire.

you have now made a solid connection between the coil and the new wire. since the new wire is sticking in the hole it is secured reasonably well. all you do to finish it off and secure it fully is to seal it up with some silicone.

it accomplishes about the same thing, but seems like it may be a little easier.  i have done it on two sets of coils with no trouble.

[Raul CB750K1]

Well, here my experience. I read about it somewhere in this forum,so I thought it was worth a try with a spare set of CB350 coils with wires rock-hard. The procedure goes like this:

Carefully cut the plastic with a dremel tool.
Unsolder the old wire, solder the new one.
Remake the plastic cover with a two-component adhesive bar, specially formulated for plastics.

[DammitDan]

I didn't know replacing the wires could make such a difference to performance.  But it certainly makes sense...

And CB650 wires are screw-on type.  Guess I'll be replacing mine ASAP! 

[malcolmgb]

 i cut the old wires off flush with the end of the coils. then i took a drill bit of the same size as the wires, and drilled into the old wire inside the coil. i drilled in about 3/8 - 

this is a job I was hoping to do.
You say you drilled out the old wire, do you mean the wire and insulation, leaving a hole big enough to push in the new cable insulation. I don't suppose you took any pictures of the work.

[mrblasty]

i have replaced wires on my 750 coils as well. what i did was a little different.

 i cut the old wores off flush with the end of the coils. then i took a drill bit of the same size as the wires, and drilled into the old wire inside the coil. i drilled in about 3/8 - 1/2". you then have a hole with the end of the wire down inside the middle.

you can then take a pin or brad nail and stick it into the copper wire inside the hole. you will need to push it in part way and leave some sticking out to about the end of the coil.

then take your new wire and stick it into the hole with the pin you inserted going into the copper conductor in the new wire.

you have now made a solid connection between the coil and the new wire. since the new wire is sticking in the hole it is secured reasonably well. all you do to finish it off and secure it fully is to seal it up with some silicone.

it accomplishes about the same thing, but seems like it may be a little easier.  i have done it on two sets of coils with no trouble.

Here are a few pics following these instructions.  picture quality aren't the best but i think it may get the point across.

[malcolmgb]

excellent, that is how I had hoped to do mine, you have given me the confidence to try soon.

[mrblasty]

Good luck, the proccess is really simple jst take your time.

[mrblasty]

update on the above thread, coils are installed, spark quality has improved, as a result the bike isn't running as rich.

break down of the cost:
$22.00 for the wires
$.50 for the brass rod
$3.00 for the sealer

$25.50 total

[Rsnip988]

you can also cut the wires off at about an inch and use NKG spark plug wire splicers that do the trick just as well with no soldering or sealant

just my .02

[mrblasty]

you can also cut the wires off at about an inch and use NKG spark plug wire splicers that do the trick just as well with no soldering or sealant

just my .02

True, but at $4.00 ea. on the splicers adds a bit to the overall cost of things.

[Rsnip988]

true   but... i said it was easier not cheaper

[malcolmgb]

you can also cut the wires off at about an inch and use NKG spark plug wire splicers that do the trick just as well with no soldering or sealant

just my .02

and in the case of my coils the HT cable is broken just as it comes out of the coil body.

[patpollin]

where can one find copper core wire to use for this operation?

[dusterdude]

napa,it may not be copper but it is metallic.

[neil young]

you can also cut the wires off at about an inch and use NKG spark plug wire splicers that do the trick just as well with no soldering or sealant

just my .02

I'm with you.i added the ngk connectors and my bike runs great.barely touch the start button and off i go.starts first kick as well

[gtyler5]

dennis kirk has copper core plug wire part #2021 6' for $2.95 cheepest price could find, good quality too.

[tntrainman]

just looking over these posts and noticed some were seeking sources for copper core plug wires.  you may find that some lawnmower shops carry in it bulk.  most shops can get it in the rotary(#8775@ $7 for 10 feet) or stens(#135-004@$17 for 20feet) parts line.  it has hypalon covering.  it is 7mm in diameter.
worked for me.

jon

[jrtruckn]

I just recently did this to a set of coils off my CB550. I had gotten instructions from a friend on how to do it. He suggested using a Dremel and start cutting about a 1/4 inch from where the wires enter, all the way to about ½ inch from the back. In my case I found one wire that had broken in the coil and I was still able to do the repair. He then said to strip some of the new wire and soldier the two together to get a good bond. Then to cover the whole thing up with High Temp RTV. I can’t soldier that well and my soldier iron was acting up but I have pictures of the whole process. I’ll get them posted as soon as I can get them downloaded from the camera.

Now the funny part is I wanted to see if the one that had the wire broken off and didn’t offer a lot to soldier too was working. I was getting ready to test it and accidently hit the starter button with my elbow while I had the wire and plug in my hand. Needless to say it works and I now have feeling back in my fingers. 

[m00ntan]

I read this post and found some copper stranded 7mm wire at the local auto shop.  It looked pretty dusty.  It's marked "High Performance Copper Conductor" and is tinned so it doesn't have the orange color.   I already bought this from eBay for something stupid like two bucks a foot so I thought I had found something special, and I bought the roll.  Nobody on eBay wants it.


I will happily mail this for 80 cents a foot plus postage, paypal.

[horning88]

My wires are broke at the coil. I drilled and inserted a finishing nail as well.... works great

[PurduePete]

Hey m00tan,

Have you still got some? I'd like about 6 feet I think. Just need it for this bike and my dirt bike. Let me know if I need more or less if you have some.

Also what kind of boots does everyone replace with? I am thinking NGK 120 degree elbow. The number on bike bandit for the specific one is VD05F. They are 5 kilo-ohm caps, which I believe is stock. Also toying with 102 degree but 120 would probably work better.


PurduePete

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[PurduePete]

Wow, just realized how old this post is. My bad.


PurduePete

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