Can the actual wires on pickup coils be COMPLETELY replaced somehow??

[ERM83]

I'm trying to clean the wiring up on my SG...it's a daily rider for sure, but I'm about to go through the whole thing...top to bottom. I just can't take the way the wiring looks. I'm about to have time to actually give it an external / internal makeover, and I'm trying to start as soon as I can.

I've had to fix the pickup wires twice now, and I wanted to see if this was an option:

I have the pickup coils wires from the 79 SF, but didn't know if that was "plug n' play"??? I don't mind swapping out wires / spade connectors from that, into a clip that would fit...just did that for my key-switch, following my tree-clothesline mishap.

I was hoping that there would be some kind of swap between the 79' coils, or being able to rewire the current ones completely. If not, should I not just get a whole new ignition?? The pickup wires were BAD on this thing...not only because they're old wires and I ride EVERY SINGLE DAY, but because the left side of the bike was the most exposed to the weather in an old garage.

I don't know how I could justify getting another used pickup coil setup, just because...I'm going to do this all over again.

Best way to remedy this situation?!

Eric

[3Phase]

Eric, all of the pick-up coils are interchangeable except the XJ1100s so that'd be your best bet if the 'new' coil is better than your old coil.

You can (question of abilty) use a Dremel or similar tool to open up the entry of the pick-up coil case and expose the wire. It's similar to replacing the old wires in the stock ignition coils but be careful if you decide to try it.

The wire in the pick-up coil is very, very, fine and if you cut too far into the case or at the wrong spot then you have a very, very, fine paperweight. DAMHIKIJKOK

[rover]

pick up coils

Go to Rice Paddy motorcycle parts, they have new pulser coils (pick up coils) for around $30

[Radioguylogs]

Me too

I replaced the broken coils on my SG with another set from eBay. The 'new' set failed in about 2000 miles.

So I cut the wires right where they come out of the coils and soldered completely new wire. I held the solder joints in the wire clamps by the coils, so the moving wires are fresh and virgin.



I feel confident I will be over 90 years old next time they fail

[donebysunday]

Rice paddy

Just got off the phone with Rice paddy the coils they had were used and are not in stock again until they get another junker in.
I think your best bet is to replace as much of the fine/very fine wire as you can, at least in the area that moves.
This wire was hard to find and I had to buy like 3 different colors in a pack, about $20, made for a remote controlled race car.
I've lots left if you need some ?
Don'e

[DELL82]

Replacing wires in Ignition Coils

The wires from the coils to the spark plugs are replaceable. By using a Dremel tool with a carbide router bit one can rout out an area next to the wires exit from the coil. Start about 1/4" to 5/16" from the exit point so as not to get into the area where the water/restraint cap snaps onto the coil.




Pix 4 shows the completed repair and filling the connection with an clear potting epoxy.
Dell

[DELL82]

I am trying to insert four pictures into the reply. Hopefully this will work. They are links to dropbox photos.

https://www.dropbox.com/s/7tbw2atdc6...pair1.jpg?dl=0
https://www.dropbox.com/s/08n28kwoh7...pair2.jpg?dl=0
https://www.dropbox.com/s/m8r6roy1b2...pair3.jpg?dl=0
https://www.dropbox.com/s/89mtht70nb...pair4.jpg?dl=0

[speedlimit85]

Thank you

I replaced the broken coils on my SG with another set from eBay. The 'new' set failed in about 2000 miles.

So I cut the wires right where they come out of the coils and soldered completely new wire. I held the solder joints in the wire clamps by the coils, so the moving wires are fresh and virgin.



I feel confident I will be over 90 years old next time they fail

I will do this too.

[rover]

coils

I thought the discussion was about PICK-UP coils.

[rover]

Yamaha J38-85580-20-00 Coil, Pulser; J38855802000

from partspak

[rover]

Yamaha J38-85580-20-00 Coil, Pulser; J38855802000

Correction: from partspac

[SFerinTEXAS]

I looked at silicone rc wires on the web. Can anyone suggest the correct size needed for the pick up coils ? either mm and/or awg .

[Radioguylogs]

Suggestion

I was really happy with this package:
https://www.amazon.com/dp/B01LZ4CGXL/ref=biss_dp_t_asn

It has all the colors to match the original wires. I studied the old wires and tried to guess the correct wire gauge. I think this choice (20#) was arbitrarily close to the original wires.

The only problem with my choice is that you are buying lots of wire you don't immediately need (for $30). You can find smaller packages of the same wire on Amazon, but you won't be able to match the colors.

Look for lots of strands and flexible insulation when you make a choice.

[jetmechmarty]

The 20 AWG recommended by Mike should be more durable than OEM. I believe that may have been 24 AWG. The weak point is where you solder it. I prefer to use an uninsulated butt splice (proper crimp tool) covered by heat shrink tubing.

[skids]

The 20 AWG recommended by Mike should be more durable than OEM. I believe that may have been 24 AWG. The weak point is where you solder it. I prefer to use an uninsulated butt splice (proper crimp tool) covered by heat shrink tubing.

I know this sounds kind of stupid, but on one of mine, I put long enough wires to make loops. This keeps the "kinked angle" at a minimum and the repair has lasted many years. If you do that, make sure there is no rubbing.