Coil wire R&R

fredgarvin · Post by **fredgarvin** » Sat Feb 23, 2019 4:16 pm

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

karl pa · Post by **karl pa** » Sun Feb 24, 2019 7:38 am

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.

tz375 · Post by **tz375** » Sun Feb 24, 2019 11:20 pm

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.

fredgarvin · Post by **fredgarvin** » Mon Feb 25, 2019 6:59 pm

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.

sportston · Post by **sportston** » Sun Mar 03, 2019 3:25 am

How is it possible to fit the new coils leads? Do they simply screw in? Or are they soldered?

karl pa · Post by **karl pa** » Sun Mar 03, 2019 6:31 am

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.

sportston · Post by **sportston** » Sat Mar 30, 2019 12:57 pm

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)

GTandcbr · Post by **GTandcbr** » Sat Mar 30, 2019 2:38 pm

Look here for help
https://www.google.com/url?sa=t&source= ... sLooCjNqXz" onclick="window.open(this.href);return false;

sportston · Post by **sportston** » Sat Mar 30, 2019 4:25 pm

That is a very useful topic. Thank you very much

Coil wire R&R

Coil wire R&R

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