New Plug wires, JUST DO IT!!

[Guest]

If you want some cheap performance, easier starting gains, better idling

Just replace those old nasty plug wires and caps with new silicone wires and caps.
I couldn't beleive how long the spark was and bright blue, for the cost of a set of Accell plug wires I got better performance

[GQROD]

What kind of coils do you have?

[first timer]

stock coils do not seperate from their wires easily or cleanly. There is no way to get stock coils to connect to silcone wires. you might have better luck using solid core copper wires and cutting the old wire a inch or so from the coil and soldering the new copper wire to the old copper wire.

[Clone]

Stock coils, the 83 coils have a plastic clip holding the wires into the coil. Then you just glue the new wires in because they are TOO FAT to be held in with the clips.

I am pretty sure with the black 16valve engine all the coils have replacable wires.

[Billy Ricks]

Years ago I replaced the wires on my stock coils. Remove the clips, yank the old wires out, and clean up any glue residue left behind. I wrapped a turn or two of electrical tape around the new wires to get a waterproof seal then held the wires secure with zip ties around the coils.

[Bribird]

I have replaced the wires on my stock coils. Just yank them out as best you can. Then take a drill bit(about 7mm or so) and drill into the hole very lightly at slow speed. Only go in about a half inch to 3/4". Then all the remainder that was glued into place should come out easily.If you want to go with a larger 8mm wire like I did.... then measure down the hole to the contact pin at the bottom and place some tape on your drill bit just shy of that measurement, and drill it out with a 8mm bit. NOTE>>>On each coil there are two wires of course, one will go deeper than the other.....do not use the same measurement for both holes.. Then on your wires you will need to trim just a bit around the end(like 3/8") that goes into the coil(make it thinner like the OE wire). For me with the Dyna wires I just needed to remove the rubber outer covering and it fit right in. Then I removed the wires and placed a bit of suzuki bond in and around the coil holes and put them together. Works great. no problems at all.

[GQROD]

Stock coils, the 83 coils have a plastic clip holding the wires into the coil. Then you just glue the new wires in because they are TOO FAT to be held in with the clips.

I am pretty sure with the black 16valve engine all the coils have replacable wires.

So the stock coils are housed in that plastic case the wires go into and it can be separated from the coil wires?

[reddirtrider]

So the stock coils are housed in that plastic case the wires go into and it can be separated from the coil wires?

Yes, the coils are encased in an epoxy housing that has two holes for the coil wires. At the bottom of those holes are needle like pins that insert into the coil wires for electrical connectivity. You can remove the old wires and put in new ones if you are careful not to screw up those pins. I chipped away at the old wires with a jewelers screwdriver. Once you start in you'll quickly see what is needed. I used a little silicone to hold the new wires in. If you go oversize, just cut the outer layer off to fit in the holes. Not difficult at all.

[doctorgonzo]

Literally the first mod I ever did to my bike was replacing the stock coils (and wires with them).

[Clone]

I have replaced the wires on my stock coils. Just yank them out as best you can. Then take a drill bit(about 7mm or so) and drill into the hole very lightly at slow speed. Only go in about a half inch to 3/4". Then all the remainder that was glued into place should come out easily.If you want to go with a larger 8mm wire like I did.... then measure down the hole to the contact pin at the bottom and place some tape on your drill bit just shy of that measurement, and drill it out with a 8mm bit. NOTE>>>On each coil there are two wires of course, one will go deeper than the other.....do not use the same measurement for both holes.. Then on your wires you will need to trim just a bit around the end(like 3/8") that goes into the coil(make it thinner like the OE wire). For me with the Dyna wires I just needed to remove the rubber outer covering and it fit right in. Then I removed the wires and placed a bit of suzuki bond in and around the coil holes and put them together. Works great. no problems at all.

DRILL OUT THE HOLES TO 8MM!!!!!
Why didn't that occur to me?

Jeez I am so dumb. That is brilliant.

Note to self, drill out holes next time you want to replace the wires.

[Clone]

So the stock coils are housed in that plastic case the wires go into and it can be separated from the coil wires?

Yes, when you pull off the coils you will see that there are little clips on the inside and outside of both wire bases. You have to be really careful to unhook the clips without breaking them, but after they are either broken or unhooked the wires will pull straight out. There is a pin at the bottom of the hole that you impale the new wire on. It is not as daunting a job as I thought.
BUT NEXT TIME I WILL DRILL THE FRIGGIN' HOLES OUT SO I CAN FIT THE WIRES IN BETTER

[reddirtrider]

DRILL OUT THE HOLES TO 8MM!!!!!
Why didn't that occur to me?

Jeez I am so dumb. That is brilliant.

Note to self, drill out holes next time you want to replace the wires.

Be careful with a drill. They tend to pull themselves into a hole when using a slightly larger bit (unless you're using a press). If you go too deap you'll shear off that little needle.

[GQROD]

This is a great thread, thanks for answering my question, i was concerned about dong this forfear of ruining the coils somehow.

[jabberjoe87]

where would one get "performance" coils and wires

[Clone]

I got a set of wires from a place that was going out of business for $2 a peice. But you can also pick up a set of 4cyl accell wires for around 30bucks at some places. Otherwise the man stickes it to you by charging you $20 each for powersport wires It's that 150% tax on anything motorcycle