Author Topic: new coils & wires  (Read 854 times)

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Offline scott jones

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new coils & wires
« on: August 30, 2019, 04:45:56 AM »
Good morning. I recently purchased new coils & end caps for my 1973 cb500. Going to put them on this weekend but I have one question for someone. When you screw on the end caps to the wires do you strip back the insulation & flare back the center wires or just leave it alone & screw on the caps? Thanks, Scott.

Offline Scott S

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Re: new coils & wires
« Reply #1 on: August 30, 2019, 04:57:44 AM »
 Leave it alone and screw on the caps.
 You can trim off a mm or two from the end of the wires to get to fresh copper.  Cut the entire thing....don't strip it back. Just cut off the end of the wires.
'71 CB500 K0
'17 Triumph Street Scrambler
'81 Yamaha XS650

Offline Deltarider

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Re: new coils & wires
« Reply #2 on: August 30, 2019, 05:26:07 AM »
Good morning. I recently purchased new coils & end caps for my 1973 cb500. Going to put them on this weekend but I have one question for someone. When you screw on the end caps to the wires do you strip back the insulation & flare back the center wires or just leave it alone & screw on the caps? Thanks, Scott.
What coils?
CB500K2-ED Excel black
"There is enough for everyone's need but not enough for anybody's greed."

Offline scott jones

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Re: new coils & wires
« Reply #3 on: August 30, 2019, 06:06:07 AM »
Thanks Scott S.  :)

Offline Deltarider

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Re: new coils & wires
« Reply #4 on: August 30, 2019, 06:52:18 AM »
  You can trim off a mm or two from the end of the wires to get to fresh copper. 
But... aren't his new? If so, postpone the trimming for later when it is needed.
« Last Edit: August 30, 2019, 06:53:53 AM by Deltarider »
CB500K2-ED Excel black
"There is enough for everyone's need but not enough for anybody's greed."

Offline Scott S

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Re: new coils & wires
« Reply #5 on: August 30, 2019, 07:36:26 AM »
 Yes.... sorry.... no need to trim anything if they're new.
'71 CB500 K0
'17 Triumph Street Scrambler
'81 Yamaha XS650

Offline Bodi

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Re: new coils & wires
« Reply #6 on: August 30, 2019, 07:44:14 AM »
It does depend on the coils. If they are like OEM and have the plug wires permanently attached just install the coils, make sure you have the correct plugs identified for each coil - 1 & 4 or 2 & 3 - route the cables properly, put the caps on the plugs and mark where on each wire they should be cut to get a good length... not short and not too long. Leave them a bit long so a little can be trimmed off for a fresh end if new caps are ever needed. If you get the plug cables right but reverse the coils, it's easy to just swap the points wire... but having them connected to 1-2 and 3-4 or other wrong connection you're screwed if the wires are too short to reroute.
Dyna and many other aftermarket coils come with sockets on the coils and a long piece of plug wire plus connectors like automotive distributor connections. The coil connectors have a rubber cap and a metal ring thing. You need to strip off about 3/8" off the cable insulation so bare wire sticks out. Slide the rubber on, some spit on the cable helps it slide easily. Bend the wire back over the insulation, slide the ring over the end (facing the right way!) and crimp it around the insulation and bare wire: the wire should go opposite the opening. Plug the metal into the coil first, it should snap in solidly to indicate correct insertion, then slide the rubber cap on. Dielectric grease on the wire and where the cap goes onto the coil will ease sliding and help get a watertight seal.
Some have the coil connectors factory installed so you have a longish wire with coil connectors already on each end.
Now route the wire as needed. One wire will be a bit longer for the plug opposite the coil location and 1-4 wires are longer than 2-3 so if you have the type with coil connectors already on, cut the longer 1-4 one first so you aren't short for it, there may not be much extra wire.
If the original rubber plug cable sleeves with the cylinder number labels are in good shape, you should use them for their extra insulation (and the number).
Finally put some spit or dielectric grease on the wire and push it in the cap pretty firmly while you screw the cap into the wire. If you look inside the wire socket on the cap you'll see what looks like a wood screw that threads itself into the centre of the cable, making a good contact with the core.

Offline scott jones

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Re: new coils & wires
« Reply #7 on: August 30, 2019, 10:52:45 AM »
Thanks for all that Bodi.  I bought new aftermarket coils from 4 into 1. I've ordered stuff from him before & been satisfied. Yes the wires are made into the coils & the ends are plain with the wire strands in the center. The set also came with new end caps, I plan on screwing the end caps directly onto the spark plug wires until snug. Then routing them to each cylinder.