Replacing HT leads on molded coils?

[rbaselt]

Has anyone successfully replaced their old, cracked plug wires on the molded type coils? I read a Yamaha tech tip that involved cutting deeply into the plastic of the coils, but would prefer a less invasive technique if one exists. TIA --Randall

[Hahnda]

I have done it by cutting into the coil and replacing the whole wire. Then using some epoxy to seal it back up.

Another way I have done it is to cut the wire near the coil but leave a few inches. Then take a drywall or similar screw and screw it into a new plug wire. Cut the head off the screw, file to a point, and then screw into wire left on coil. Finish off with the proper size heat shrink tubing.

[djohns]

I just pulled the leads out of the coil on my CA77. If you look on the bottom side of the coil where the high tension leads exit, after scrapping away any "epoxy" covering that area, you will see the end grain of a bamboo skewer. Drill out the skewer carefully and the wire will come out with some coaxing. remove what wire insulation and epoxy remain in the wire hole. Be careful as at the bottom of each wire hole is a 1/2"? spike that the high tension wire core is impaled on. The two holes have different depths as you may see by the amount of insulation that was in the epoxy of each. With all the holes clean of the sealant (epoxy?) push the new high tension wire down over the spike(s). Drive a new bamboo skewer into the bottom hole angling it to miss the wire core. Snip off the remaining skewer and pour 5 minute epoxy in the area between the HT wire and the molded coil. I mixed some glass beads in my epoxy which made it stiffer and molded it like the original. Talc powder works the same. It worked!

[rbaselt]

Great info, guys, thanks. I'll give it a try tomorrow. --Randall

[Mike P]

Hi Gents, New to the forum and to CA77's........

Great info on replacing the plug wires, but can you get replacement leads and boots? or can you remove the wire from the boot end also and just replace the wire only?

any info appreciated. Thanks

[neus68]

I just purchased a roll of solid core wire from Summit Racing. It is made by taylor. It is a multi solid core strand for racing applications, but it worked just fine.

[ggray]

While we're on the subject of coils, the two off my CL77 have two studs each for the electrical leads. The studs have a very sharp point and I'm afraid they'll puncture the new terminal boots I just purchased for them.

Any danger of damaging the integrity of the coil if I grind off the sharp points to reduce their height?????

Gary