Replacing spark plug leads

[Hepcat]

Has anyone ever tried splicing the wires? I'm going to try it...I have no continuity across one of the coils from the spark plug end but the coils themselves check out from the other end. The other coil is just fine. I'm nowhere near the tools I'd need to replace the wires here and I'm looking for the quick fix.

First I'll trim the wire back until I've got continuity no matter where I bend the wire, then I'll butt-connect the wires, (Doubled back on themselves to make them thicker) then cover the splice with rubber hose (Fuel line or something like that) and top it all off with a heavy wrapping of "stretch to seal high temperature self-fusing waterproof silicone tape." It's great stuff and tends to insulate a little better than electrical tape in my experience. Plus, once the self-fusing part kicks in, it becomes pretty much one solid mass and you can't peel it off anymore...it behaves more like solid rubber. In fact, there's no adhesive so it doesn't leave the annoying residue like electrical tape does. Plus, it's waterproof! It's great stuff, but more expensive than electrical tape.

Hopefully that'll get me by for a couple weeks until I go home for the summer and have access to our machine shop. I just have to remember to bring the coils back with me next Fall...

[Ken Talbot]

There's an article in the tech repairs section you should read....

[Hepcat]

I'm trying to avoid buying more tools here at College. I've got a Dremel at home but no access to one here. I just want to get by for the last 3 weeks of school until I fly back home and can fix it properly. I can't leave the bike in the school parking lot over the summer, so it's going to a friend's house. However, I need to be able to drive it there. I'll just take the coils with me for the summer.

Right now it's got no spark whatsoever. I've been busy with classes all week and won't have much time to work on it until tomorrow. I took out the battery and stuck it on the charger as it was suggested that the battery may be too low to produce the starting spark, but strong enough to turn the engine over. I went out and bought a voltmeter and just tested across the spark plugs...it was dark and raining and I didn't want to take the tank off at that point. From 1 to 4 I got an acceptable reading. From 2 to 3, I got no reading whatsoever. No continuity means it's either a broken spark plug lead, or maybe I'll find out it's in the windings when I test the primary wires.

I hope that clears it up a little bit. I'm aware of replacing the whole thing, I just can't do it with the tools I have here currently and don't feel like spending big bucks to get it to run for 3 weeks when I could spend a couple bucks on a butt connector and spark plug wire and just fix the coils at home this summer.

Thanks!

[stevec5000]

You can use the stock 2.5 ohm coils off a Harley Sportster. They use standard car sparkplug wires, go for as little as $5.00 on ebay and have a better spark than the weak original equipment coils.