Slight modification to ASH's Ignition coil fix

[SteveW]

Started to follow ASH's excellent ignition coil fix instructions, but wondered if the same result could be achieved with only cutting a small amount of the casing away.

I cut a small access hole as in the picture with a Dremel with one of those metal burr attachments. Cut through the old HT lead and yanked it out easily.

Ran a 7mm drill bit through the hole vacated by the HT lead, just to clean it out, virtually no material was removed.
Tinned the remains of the old HT lead. Stripped the end of the new HT lead and tinned.
Slid new HT lead up the hole to meet the old one, soldered together and dropped epoxy into the hole.

[UK Pete]

Wow what a good job I won't be throwing old coils  out any more

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[JamesH]

That is very cool indeed...

[Green1]

Will it suffer from water ingress though due to water running along the HT lead?

[AshimotoK0]

Will it suffer from water ingress though due to water running along the HT lead?

Cool  ..you could coat the wire in liquid epoxy then push in to fully seal. I would recommend the liquid epoxy i used in the writeup though .. very runny with heat and good dielectric strength.

[SteveW]

Will it suffer from water ingress though due to water running along the HT lead?

The old HT lead wasn't secure in the coil housing, it was literally held by the end of the cable. Once the cable was cut it easily pulled out.
The new cable is 7mm and its a perfect fit in the hole. I suppose water could possibly get in but a tiny bit of silicone sealant would stop it.

[Green1]

Interesting I thought they were sealed.
You would think the damp would get too them.

[AshimotoK0]

Interesting I thought they were sealed.
You would think the damp would get too them.

Some of them , particularly the Honda twins,  ones have epoxy smeared around the exit of the HT cable. Best to try to wipe any plasticiser etc off the inserted bit and slightly abrade to get a bond.

BTW if you tried that method with the Honda twins ones you would need to identify the wooden (yes wood!) dowel that anchors the cable and drill it out, then it would work OK. The twins are not soldered they just push into a pin inside the coil but can be soldered on repair.

[Green1]

When I eventually do mine I will seal them up as I don't shy away from the rain and it drives me crackers when they start coughing & farting.   

Saying that the mega cheap coils I bought on eBay are holding up well I noticed there completely sealed with some sort of epoxy.

[AshimotoK0]

When I eventually do mine I will seal them up as I don't shy away from the rain and it drives me crackers when they start coughing & farting.   

Saying that the mega cheap coils I bought on eBay are holding up well I noticed there completely sealed with some sort of epoxy.

If you get mega cheap ones make sure primary is around 4 to 5 Ohms minimum otherwise on standard points, the points won't last too long.

[Green1]

I never checked the Ohms but they have been in there for some time now.
The used points that were in the bike when I bought it about 5 years ago still haven't needed to be touched.

[AshimotoK0]

One thing to watch with modified method is that in some coils I have don,  on Honda 4's,  (e.g.a pair Trigger had done), the HT cable 'snakes' within the potting. I will give it a whirl sometimes though  and give it as an option in the write-up...obviously accredited to you Steve 

[UK Pete]

I have lost track of the amount of coils the ht lead has come loose in they seen to be able to twist inside the hole easily if the mod is done it is worth glueing  the cable so it don't twist
I had my engine running in my test bench using a set of coils whete I could pull the lead out of the actual cool housing it still ran ok though


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[MrDavo]

My original 45+ year old CB750 HT leads had gone rock hard, and I was getting all kinds of poppage and bangage that nothing would fix. Thinking they were sealed for life and unreplaceable I bit the bullet and bought a new set of OEM coils with leads from Mr Silver, at over £200 I have bought good, running bikes for less.

It cured all the missing and plug fouling, but I wish I'd seen these fixes first! 

[SteveW]

Just replaced the other lead on this coil (the shorter lump).

Just a note that this cable seems to be set into the potting a bit deeper than the other so the hole will have to be made slightly deeper.

Again, just like the first cable, once I had cut through the cable it pulled out easily.

Got the cable and new plug caps from these guys, cable was about £1 and plug caps about £2.50, delivered in a couple of days.

http://www.gsparkplug.com

    GPLPVCB-GS - 7mm HT Ignition Lead Cable - Wire Core PVC Black
    XD05F-B-GS - 1x NGK Resistor Spark Plug Cap XD05F black (8072)
    VD05F-B-GS - 1x NGK Resistor Spark Plug Cap VD05F black (8052)