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Nifty trick for replacing plug wires

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    Nifty trick for replacing plug wires

    Howdy folks.

    Today, I pulled my coils off my bike and replaced the wires and wire-ends. First of all, WOW. I bought an electric impact wrench for work, and WOW. It's the best tool I never knew I needed before.

    Anyway, there is an epoxy or glue that holds the original wires into the coil. The guides for it I've seen say to chip or scrape away the epoxy, but I found that made it easy to cut the plug wire, which made it quite hard to get ahold of it to pull it out.

    Here's my method:
    Rather than using a knife on the expoxy, grab it with a pair of flatnose (or needle-nose) pliers and twist around 2-3 turns. It should all come off pretty much in one piece.
    Then pull the wire core out. A thin layer of the wire's outer sleeve will be left in the coil. This is easy to remove with a long thin knife (like 3"x1/4") or something else to pull the sleeve loose.
    Once the sleeve is loose, push one side of it into the center so you have a shape like (< and grab the < portion with needle-nose pliers. Twist and pull firmly and slowly and it should come out in one piece.

    When you reinstall, the easiest way to do it is to apply a bead of silicone around the coil end of the wire about 3/8" from the end and spin the wire as you insert it. This will give you a bit of adhesive to hold the wire in, and also will waterproof the outside. Note that the two different wires on each coil insert different lengths.

    Hope that helps somebody!

    #2
    I am about to do some coils and was wondering what folks use as the adhesive around the wire where it meets the coil body. I am thinking just some simple 5 minute epoxy will do the trick???? Wonder how that silicone handles the heat from the coils and being above the hot engine as well???? I was over on Cliffs website and could have sworn there was a wire replacement tutorial...anyone know where thats at???
    Last edited by chuck hahn; 08-07-2015, 04:35 PM.
    MY BIKES..1977 GS 750 B, 1978 GS 1000 C (X2)
    1978 GS 1000 E, 1979 GS 1000 S, 1973 Yamaha TX 750, 1977 Kawasaki KZ 650B1, 1975 Honda GL1000 Goldwing, 1983 CB 650SC Nighthawk, 1972 Honda CB 350K4, 74 Honda CB550

    NEVER SNEAK UP ON A SLEEPING DOG..NOT EVEN YOUR OWN.


    I would rather trust my bike to a "QUACK" that KNOWS how to fix it rather than a book worm that THINKS HE KNOWS how to fix it.

    Comment


      #3
      Depends on the silicone, some of it is very high temp stuff.

      I haven't done it myself but one guide that I remember reading used 5-minute epoxy to hold the wires in.
      Charles
      --
      1979 Suzuki GS850G

      Read BassCliff's GSR Greeting and Mega-Welcome!

      Comment


        #4
        For the life of me I cant remember where i saw the tutorial....had pics and a list of adhesives etc etc.
        MY BIKES..1977 GS 750 B, 1978 GS 1000 C (X2)
        1978 GS 1000 E, 1979 GS 1000 S, 1973 Yamaha TX 750, 1977 Kawasaki KZ 650B1, 1975 Honda GL1000 Goldwing, 1983 CB 650SC Nighthawk, 1972 Honda CB 350K4, 74 Honda CB550

        NEVER SNEAK UP ON A SLEEPING DOG..NOT EVEN YOUR OWN.


        I would rather trust my bike to a "QUACK" that KNOWS how to fix it rather than a book worm that THINKS HE KNOWS how to fix it.

        Comment


          #5


          Mighty Putty.
          David
          1998 Suzuki Bandit
          1978 GS750 gone but not forgotten
          1978 GS1000 - gone
          1981 GS850 - gone

          Comment


            #6
            Saw that one Dave..but it was more about soldering a failed joint and covering with the putty. This tutorial had pics of the pin down the hole etc etc....

            I think I am gonna take a 2 step approach. Highest temp silicone I can find for sealing the wire inside the hole for water tightness purposes.. followed by a bed of 5 minute epoxy around the base to secure the wire to the coil body.
            MY BIKES..1977 GS 750 B, 1978 GS 1000 C (X2)
            1978 GS 1000 E, 1979 GS 1000 S, 1973 Yamaha TX 750, 1977 Kawasaki KZ 650B1, 1975 Honda GL1000 Goldwing, 1983 CB 650SC Nighthawk, 1972 Honda CB 350K4, 74 Honda CB550

            NEVER SNEAK UP ON A SLEEPING DOG..NOT EVEN YOUR OWN.


            I would rather trust my bike to a "QUACK" that KNOWS how to fix it rather than a book worm that THINKS HE KNOWS how to fix it.

            Comment


              #7
              Did my 750 coils yesterday, 5 minutes epoxy. All seams good, used Volvo penta boat engine leads
              My bikes 79 GS1000 1085 checked and approved by stator the GSR mascot :eagerness: and 77 GS750 with 850 top end, GS850g, and my eldest sons 78 GS550, youngest sons GS125. Project bike 79 GS1000N

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