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 Post subject: Coil wire R&R
PostPosted: Sat Feb 23, 2019 4:16 pm 
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Still in the Driveway

Joined: Sun Nov 04, 2018 3:04 pm
Posts: 7
Country: United States
Bikes owned: 72 ts 185 765 gt750
Greetings,
I pulled the old coil wires out of a 76 750, but i am having trouble finding suitable replacement wires. I am looking for red 7mil cooper with a 90 degree red cap since I read here that the silicone ones are trash. My real issue is that I can't find a 7mil wire for the cap with a reduced diameter for the coil. Some of the silicone wires have the reduced diameter for the coil from what I can see on some of the photos. I can purchase bulk 7mil cooper wire in the desires length, but not sure how to reduce the other end to fit in the coil.
Any suggestions would be appreciated.

Thanks


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 Post subject: Re: Coil wire R&R
PostPosted: Sun Feb 24, 2019 7:38 am 
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On the main road

Joined: Sat Sep 05, 2015 3:14 pm
Posts: 185
Location: southeast pa
Country: us
Bikes owned: GT
Did you remove the old epoxy that held the old wire in ? I replaced wires on 2 coil packs with 7mm wire, it fit nicely in coils and NGK non resistor caps, I bought 5 ft wire and cut to length. Make sure to epoxy new wires in coil to keep them secure.

_________________
76 GT185
77 GT250
77 GT380
76 GT500
73 GT550
73 GT750
74 GT750
71 T250 scrambler
75 T500 cafe


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 Post subject: Re: Coil wire R&R
PostPosted: Sun Feb 24, 2019 11:20 pm 
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Moto GP
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Joined: Mon Nov 03, 2008 10:47 am
Posts: 6074
Location: Illinois
I just measured a couple of coils that I removed the HT leads from and they are around 7.5mm, so as long as the 7mm leads are not oversized, you should be good to go once you dig out the old epoxy.


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 Post subject: Re: Coil wire R&R
PostPosted: Mon Feb 25, 2019 6:59 pm 
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Still in the Driveway

Joined: Sun Nov 04, 2018 3:04 pm
Posts: 7
Country: United States
Bikes owned: 72 ts 185 765 gt750
There was some of the coil wire sheathing left in the coil when I pulled out the wire. I took a 6.8mm drill and removed it. Problem solved.


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 Post subject: Re: Coil wire R&R
PostPosted: Sun Mar 03, 2019 3:25 am 
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Expert racer

Joined: Wed Jul 10, 2013 12:04 pm
Posts: 1024
Country: England, UK
Bikes owned: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S
How is it possible to fit the new coils leads? Do they simply screw in? Or are they soldered?


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 Post subject: Re: Coil wire R&R
PostPosted: Sun Mar 03, 2019 6:31 am 
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On the main road

Joined: Sat Sep 05, 2015 3:14 pm
Posts: 185
Location: southeast pa
Country: us
Bikes owned: GT
Suzuki had two types of coils, grey and cream colored, my understanding is that the grey ones can't be repaired, but the cream colored ones can. The coil has a spike in the hole the wire pushes on, the wire is epoxied in place, the trick is to remove the wire and epoxy without damaging the spike.

_________________
76 GT185
77 GT250
77 GT380
76 GT500
73 GT550
73 GT750
74 GT750
71 T250 scrambler
75 T500 cafe


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 Post subject: Re: Coil wire R&R
PostPosted: Sat Mar 30, 2019 12:57 pm 
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Expert racer

Joined: Wed Jul 10, 2013 12:04 pm
Posts: 1024
Country: England, UK
Bikes owned: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S
Ah that is very interesting and useful. Thank you. I have a set of the old cream ones so I might be able to replace the leads. I didn't realise that. I'd put a cheap set of new modern ones but was not impressed with the quality of their leads at all (very thin core and not very flexible rubber)


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 Post subject: Re: Coil wire R&R
PostPosted: Sat Mar 30, 2019 2:38 pm 
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To the on ramp

Joined: Tue Mar 10, 2015 12:35 pm
Posts: 493
Location: Wales
Country: WALES
Bikes owned: suzuki gt 550j
Look here for help
https://www.google.com/url?sa=t&source= ... sLooCjNqXz

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98 carb Blackbird and GT550j


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 Post subject: Re: Coil wire R&R
PostPosted: Sat Mar 30, 2019 4:25 pm 
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Expert racer

Joined: Wed Jul 10, 2013 12:04 pm
Posts: 1024
Country: England, UK
Bikes owned: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S
That is a very useful topic. Thank you very much


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