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I just installed Dyna 3 ohm ignition coils (the green ones) on my ’82 GS 850 G. Dyna provides crimp connectors on the 12-volt side that screw into their coils with 10-32 screws. However, the original coils have ¼” blade connectors that fit into our original wiring harness. To use Dyna’s connectors, it requires cutting off the female blade connectors from the original harness and then solder on new ones. Here’s a way to leave the original wiring harness untouched.
The idea is to get four connectors with a regular ¼” blade on one end, and a 3/16” hole on the other end. That connector (about 3/4” overall in length) is screwed into the new coil using Dyna’s 10-32 screws. However, I found no connector like that. So I decided to buy connectors with a regular blade on one end and a round wire connector on the other end, then:
1) Smash the round wire end flat with a vise
2) Drill out the smashed end to 3/16” so it fits a 10-32 screw.
I went to the local hardware store, and they had blade connectors, but the other side was made for wire of pretty small diameter. When I smashed the round end flat with a vise, there wasn’t enough area for a 3/16” hole.
Blade connectors that accept BIG gauge wire are available. 12-10 AWG .250 Tab wire connectors from JT&T work (part #2377J). Amazon carries this part, but I got mine locally from Fry’s Electronics. Smash the round end with a vise, centerpunch it, then start drilling at 1/16” and go slowly by degrees with larger drill bits to 3/16” (be careful, you’re drilling through pretty soft metal).
When you’re finished drilling at 3/16”, these connectors can be screwed in with Dyna's screws straight into the green coil, and you have a blade on the other end just like the original coils.
I know this process is pretty labor intensive just to get 4 little connectors that work. If somebody knows how to order this part from a catalog, that would be great.
The idea is to get four connectors with a regular ¼” blade on one end, and a 3/16” hole on the other end. That connector (about 3/4” overall in length) is screwed into the new coil using Dyna’s 10-32 screws. However, I found no connector like that. So I decided to buy connectors with a regular blade on one end and a round wire connector on the other end, then:
1) Smash the round wire end flat with a vise
2) Drill out the smashed end to 3/16” so it fits a 10-32 screw.
I went to the local hardware store, and they had blade connectors, but the other side was made for wire of pretty small diameter. When I smashed the round end flat with a vise, there wasn’t enough area for a 3/16” hole.
Blade connectors that accept BIG gauge wire are available. 12-10 AWG .250 Tab wire connectors from JT&T work (part #2377J). Amazon carries this part, but I got mine locally from Fry’s Electronics. Smash the round end with a vise, centerpunch it, then start drilling at 1/16” and go slowly by degrees with larger drill bits to 3/16” (be careful, you’re drilling through pretty soft metal).
When you’re finished drilling at 3/16”, these connectors can be screwed in with Dyna's screws straight into the green coil, and you have a blade on the other end just like the original coils.
I know this process is pretty labor intensive just to get 4 little connectors that work. If somebody knows how to order this part from a catalog, that would be great.