Replacing wires on stock coils

[catbed]

Has anyone actually dug the the old wires put of the coils to replace the wires? My wires are looking tired from their 27 years of existence, and they have only just begun arcing when the bike is idling. If you have done it, got any pictures or advice to share?

[Dave8338]

Yes, just not on a GS. They are glued in and need to be somewhat forcefully removed. Dig out the old and insert the new. Measure the plug wires to ensure that the new ones will fit snugly otherwise, you'll have a heck of a time, getting them back in though it can be done.

[BassCliff]

Hi,

Mr. Wallowgreen has performed this surgery and posted some pictures. But because of the work going on with the GSR server, none of those posts with the pictures are available right now. I think I have the pictures on a computer at home. Basically, you just carefully chip away at the epoxy glue until the plug wires pull out of the coil. You might have to clean up the holes in the coils being careful not to damage the spike at the bottom of those holes. Then just push your new wire in and re-glue.

I'll see if I can find the pictures after I get home.


Thank you for your indulgence,

BassCliff

[crag antler]

The wires on my 1100E were cracking and I was considering doing the surgery.
But after realizing the age of the stock coils, 24 years old, I just went to www.Z1enterprises.com and bought a new set of Dyna coils and wires.
That way I was assured of perfect coils and wires I could replace if needed.
Just a thought.

http://www.z1enterprises.com/detail.aspx?ID=210

http://www.z1enterprises.com/detail.aspx?ID=1983

[Octain]

Its easy.
Just be careful of the little pokers or pointy things at the end of the holes.
Yank em out trying to get as much of the rubber ya can. I used a loose fitting drill bit to remove the remaining junk. Wrapped around the bit and came right out.

Discount part stores should have some assorted 7mm wires. I simply purchased two 7mm wires about 4 foot long and cut as desired. Less than 10 bux.

[nastyjones]

I figured my coils & wires were both tired so I bought a set of Bandit coils off Ebay, dug the old wires out (pain in the a**) and replaced them with Dyna wires from Z1 for something like $17.00. You need to be careful but completely doable with great results.

[Wallowgreen]

Yep as Mr. BassCliff says, I've done this on my 850, easy job so long as you don't rush. Cut away the epoxy around the top of the wire where it enters the coil body with an xacto knife or similar then use something like a dental pick to remove epoxy down in the recess the wire goes in to the coil. Keep going and eventually the wire will just pull straight out.

I went to NAPA and got replacement wire at about 50c a foot I think, cut it to length then put a bead of high temp RTV about 1/2" from the end of the wire before pushing it down on to the spike at the bottom of the hole in the coil body. Then finished with a bead around the top to mimic the original as best I could.

Here's a post with some pictures, sadly the report I wrote up wasn't available last I looked.

http://www.thegsresources.com/_forum/showpost.php?p=1157916&postcount=18

[greg78gs750]

when i did mine i put a bit of heat shrink tubing around the wire at the insertion end, snugged the fit up a bit, just perfect.

[cdnoel]

Be ready to get GSX-r coils.

I've had luck replacing the wires on one set of GS coils and ruined another set. On one set the wires pulled out and nail type pins were available inside for the new wires to be glued back in. On another set I pulled out the wires and found only ripped apart wires inside.

The good news is you can get a set of GSX-r, Bandit, or Katana coils for under $20.00 from e-bay. The wires on them probably wont need to be replaced but if they do they are cliped in instead of glued. The clips are fragile but if you have some finesse you can save them.

Either way you are looking at getting about 6ft of solid core wire from the dealer and some NGK resistor caps.

[catbed]

just to update everyone, i ended up using some newer VW wires off an engine I have. Chipped the old epoxy out of the coils and removed the wires. Put some silicone on the "new" wires and pushed them in. I then re-installed them and now the bike runs and idles great! No more arcing at idle and it runs amoother all around.

Thanks for all the help everyone!

[SqDancerLynn1]

Note: If you use automotive suppression wire use standard auto ends.
If you use solid wire like the originals re use the plug caps or install new NGK plug caps on your new plug wires

[catbed]

^^ good point.

i used solid core wires with the original resistor caps.