Super Jet Is there a "how to" that outlines rebuilding oem coils? Specifically the wire?

[hondamxracer]

I would like to replace the coil wires on my oem yamaha coils. I know several vendors offer this service (e.g., JSS), but does anyone know of any "how to" posts if I'm interested in doing it myself?

 

[SuperJETT]

I've rewound coils before, though not any ski ignition coils. You have to disassemble one, measure the wire and count the turns and measure the resistance then rewind. I don't remember seeing the wire gauge/turns anywhere before.

 

[hondamxracer]

I should have been more specific in my post. I am looking to replace the coil wire that runs between the spark plug cap and the coil.

 

[AtomicPunk]

There is a thread from a few years ago.... unless you know what you are doing, JSS is pretty hard to beat. Plus you can also get "JSS" coils from Jetmaniac...

 

[SuperJETT]

Haha, gotcha. I did replace my coil wires myself once and they worked just fine but eventually went with a JSS coil.

 

[SuperSteve]

its pretty simple... Ive done a couple. Just cut the wire at the base of the housing then get a drill bit that's the same size as the new wire and drill it out VERY CAREFULLY until you feel it bottom out. I drilled mine by hand(no drill). There is a prong in the center of the wire hole on the coil that will go INTO the new wire to make contact. After you get to that prong, youll have to get a small flathead or anything to get the rest of the rubber and wire out from the edges. After its all cleaned out, make sure the new wire fits into the coil. I applied some dielectric grease to the prong and epoxy to the outside of the wire, stick it in there nice and tight and let it dry!

 

[Midlake Crisis]

I am pretty frugal and have done this, and agree that JSS via Jetmaniac is the way to go unless you are really enjoying the project aspect of it.

 

[augustaf]

I used a 1/16" slitting wheel to modify drill bits for this, so I would straddle the pin. I had sawed open a coil to see what's inside- pin is about 1/8" longer than the window shows. The pic showing the coil repaired with NGK wires was not very cost effective- too expensive.
I've also used Taylor wires- easy to install, or 8.5mm carbon wires- difficult to connect to the coil pins.

 

[augustaf]

Found a pic of some coil repairs I did with the previously mentioned MSD wire- a bit labor intensive, but I felt that was needed to alleviate RFI to work with my EPIC ignition modules

 

[hondamxracer]

its pretty simple... Ive done a couple. Just cut the wire at the base of the housing then get a drill bit that's the same size as the new wire and drill it out VERY CAREFULLY until you feel it bottom out. I drilled mine by hand(no drill). There is a prong in the center of the wire hole on the coil that will go INTO the new wire to make contact. After you get to that prong, youll have to get a small flathead or anything to get the rest of the rubber and wire out from the edges. After its all cleaned out, make sure the new wire fits into the coil. I applied some dielectric grease to the prong and epoxy to the outside of the wire, stick it in there nice and tight and let it dry!

I'll take your approach of drilling by hand and will make sure to use some dielectric grease before I epoxy or JB weld the wires back in.

I am pretty frugal and have done this, and agree that JSS via Jetmaniac is the way to go unless you are really enjoying the project aspect of it.

I think you nailed in on the head. It's more of the project aspect of it.

Found a pic of some coil repairs I did with the previously mentioned MSD wire- a bit labor intensive, but I felt that was needed to alleviate RFI to work with my EPIC ignition modules

I do have an EPIC, so it sounds like I need some special wire. Can you elaborate a bit more?

My local o'reily's has 7mm solid core wire. I'm not sure of the brand at this time.

 

[hondamxracer]

Anyone?

 

[augustaf]

I do have an EPIC, so it sounds like I need some special wire. Can you elaborate a bit more?

You could use NGK spark plug boots which have a 5k ohm resistor built in. That should work.

 

[pwcbret]

This is a superjet coil but the same coil is used on many Kawi's. You would need to bore down 39-40 mm to clear out the old wire. I used a drill bit with a slot slit in the end and hand drilled A death wheel (abrasive wheel)can cut the slit in the drill bit. The pin (not shown) is about 10mm long.

 

[modularjunk]

@pwcbret i dont know if you knew this was a year old thread but opening up a coil that much will probably cause problems esp sealing it up tight

 

[Quinc]

I posted a thread with step by step pictures a few months ago in the driveline sub forum.

 

[pwcbret]

@pwcbret i dont know if you knew this was a year old thread but opening up a coil that much will probably cause problems esp sealing it up tight

I knew the thread was old but when I searched for info on this, it is what came up. My buddy ruined this coil by breaking the pin off so, I cut it apart to see exactly how deep it needed to be. My post was just to help someone out if they were going to do this themselves since I was left wondering how deep it actually needed to be drilled after reading a few different forum threads. There were plenty of threads saying what to do but I didn't find any that said exactly how deep it needed to go.