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Spark plug wire splicing?

  • Thread starter Thread starter wkmpt
  • Start date Start date
W

wkmpt

Guest
I have a set of bandit 600 coils I want to install, but the plug wire for cyl. #1 is too short.

Anybody have any experience with the NGK spark plug wire splice? It's mentioned on one of the kwaker forums, but I wanted to see if anyone has any GS-specific experience with them.

Any other suggestions for the plug wire length issue?

Thanks in advance for your time.
~Matt
 
Carefully remove the existing wire (it can be done) and reinstall one that is the right length.
 
Okay, got the wire out. The wire that was previously in the Bandit coil is covered in a gray rubbery substance. Is that a dielectric sealer of some sort? It's also all over the pin on the inside of the coil, is that going to cause problems making contact with the new spark plug wire?
 
Are you going to install thoses coils in your '77 with points ignition? If so, they won't work, the resistance is too low. Don't mean to sound critical, just trying to warn you.
 
Nessism said:
Are you going to install thoses coils in your '77 with points ignition? If so, they won't work, the resistance is too low. Don't mean to sound critical, just trying to warn you.
Click to expand...

Seriously, thanks for the heads-up. I had completely forgotten about the subject of impedance, glad you reminded me before I blew up my new coils. Fortunately, I have a Dyna S that's going on the bike as well, I'll make sure it goes on before the new coils do.
 
Get an old distributer cap. Cut out the plug wire sockets with a dremel tool or exacto saw leaving lots of extra material to work with. Drill a hole in each rotor contact post on the inside of each piece. Cut the existing plug wires off at about 3 inches. Strip the insulation off the last 2 inches (carefully - don't want to lose strands). Thread the exposed wire through the hole in each contact post until the insulation is just short of touching the post. Wrap the wire around the post tightly and solder. Trim the extra material on the cap pieces so that you can build up epoxy around the insulated wire until the cap socket is epoxied to the coil body.
You now have coils that will accept replacement plug wires!

I have done this and as long as you don't use a metal bearing epoxy like 'Liquid steel', it works quite well.
 
The wire splicer will work fine. You might want to take a close look at the coils first though, some of the later GS coils have little plastic clips holding the coil wire into the coil - the wire is removable on that style of coil.

BTW, what is wrong with your original coils? Suzuki used high quality parts that rarely fail. I'd use the stock coils unless you have a reason not to. The Dyna S is designed to work with stock coils so you are good to go. Those Bandit coils could be used with points but you need to add a ballast resistor to increase the impedance.

Good luck and keep going...
 
splicing is a BAD idea get coils that have removable wires and keep the wire in 1 piece from coils to plug cap.


wkmpt said:
I have a set of bandit 600 coils I want to install, but the plug wire for cyl. #1 is too short.

Anybody have any experience with the NGK spark plug wire splice? It's mentioned on one of the kwaker forums, but I wanted to see if anyone has any GS-specific experience with them.

Any other suggestions for the plug wire length issue?

Thanks in advance for your time.
~Matt
Click to expand...
 
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