Replacing Plug Wires

[Scudder]

I'm thinking of replacing the plug wires on my 1980 gs850. The plug wires run directly out of the ignition coils. How would I replace the wires?

thanks

scudder

[Redman]

Has been many posts about this.

But in general, the weires were not really meant to be removed from coil and replaced.
But many have done it. Have to dig the wire out from the coil without breaking the post/pin/wire/contact in there. You might break it and then need another coil.
Do not need the resistor wires (like most automotive wires), because the motorclycle caps have the resisitor in the caps (unlike automotive) .

Can search and find other post with more details.

You didn't ask about the caps, so I gather you know that those do easily twist-pull off, and are meant to be replaced, and do go bad. In fact, the caps are much more likley to go bad than are the wires.




Then, after you take care of all this, you can post more about your intended Michigan trip around Lake Michigan and see how many Michiganders have some info for you and/or can join you for part of it and maybe lead you to some interesting places. (I have some in mind).

.

[chuck hahn]

Here is my quicky method..

1.. take a bench grinder and go along the HUMP that the wire makes onn the outside of the coil and dust off the plastic on the coil case. Go down jsut till you hit the rubber wire casing. Grind all the plastic off till youre at the ends of the wires.

2..remove the old wires out of the ditch and off the pins.

3..insert the new wires onto the pins.

4..mix up a big batch of 5 minute epoxy and fill over the new wire to rebuild the outer case of the coil you ground off. and let it hareden up.

5..take a rough file and reshape the epoxy to look nice and repain them if you want. Repainting iosnt needed, but it looks nice.

Now you have a new wire ( which you know is making contact with the pin) and its epoxied into the coil..goo to go for the next 20 years or the coil fries..whichever comes first.

[kokar]

there is a special equipment from NGK for this job
NGK Spark Plug Cable Splicer J18083

http://www.lyris.gr/product-view.aspx?pid=34054

[Scudder]

Thanks for the advise on the plug wires. I'm still trying to solve the loss of power when I hit rain. It happened one on the Tennessee trip, but the rain let up and the power returned. I've gone through the bike to find the electrical problem, and I've found a couple things in my fairing wiring (exposed wires) that could have maybe been an issue. Also, on the way to the tail of the dragon in Tennessee, my horn spontaneously went off and won't stop so I had to disconnect it. Obviously there was ground somewhere with that. Just starting the process of elimination. Plug wires are a part of that process.

Redman. Thanks. I will be leaning on you Michigan guys as the UP trip approaches, for your knowledge. Michigan's a great state. I spend several weekends in Michigan a year. Mainly in the Fall, when the Salmon run up the Pere Marquette River.

Scudder