550 coils and wires

[mack]

Can you change the wires without changing the coils?

[Nessism]

Wires are molded into the coils. I've heard of people digging out the old wire but there is no guarantee that it will come out without destroying the coil.

http://www.xs11.com/tips/repair/repair24.shtml

[brveagle]

You can splice the two wires together. I did that for a few thousand miles.

But properly? NO

[gke84]

550 coils and wire

i have done three sets of coils and every one came out perfectly.first step take off the blob of epoxy on the end of the wire that goes into the coil,taking care not to cut the wire.some times by taking a pair of pliers and twisting the wire it will come out.if not ,using an exacto knife cut the rubber casing, exposing the copper wire.pull on it and it should come out .now with some patience and a small pick or whatever you have, gently pry it out.when its all out ,clean every thing with some laquer thinner.now you will see a small metal pin inside the coil,try and clean it and you will be ready to put in the new wire.measure from the bottom of the metal pin to the outside of the coil.now make a mark on the wire so you will know how far to push it in.scuff the wire that goes into the coil,spread the copper on the end of the wire to center it on the pin.now you will put some epoxy or jp weld on the rubber part of the wire.do not get any epoxy or jp weld on the pin or the copper wire.hold the coil with the opening down and twist your wire in to the mark on the wire.now you can put a blob of epoxy or jp weld on the coil ,the same as it was before.it may be better to use jp weld because i think its a bit thicker than epoxy.good luck

[Regent]

You can splice the two wires together. I did that for a few thousand miles.

But properly? NO

I believe I did mine properly, and without hacking the crap out of the stock coils as outlined in the above link. :shock:

I broke the epoxy sealing the wires in by using a pliers and a sharp awl. Then I dug down in there around the wire about 1/2 an inch to free it up a bit more, and the wires in 3 of 4 holes pulled out clean as a whistle.

The last one broke off half way down inside the hole.... but I tool my time - a full hour - and slowly and carefully dug it out of there with a long slim awl. The pin was slightly bent when I was done... and I straightened it.... like i was diffusing a bomb. Very damn carefully. Now all that was left was to cut the wires to size, push them in, (test continuity) and seal them in there at the opening with some JB Weld "Quick".

I wouldn't have cared if it took half a day to dig them out - new coils to replace perfectly good ones isn't a reasonable option if you're on a budget, and they're expensive as hell.

They'll throw a blue spark across a 20k volt gap, so I guess it got done right. ;-)

Edit:
I see after writing it up that gke84 has already covered the same ground... and very well at that. I'll just toddle off to bed, lol.