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Katana How-To's & FAQ's A forum filled with write-ups, FAQ's, and visual aids for
mechanical & cosmetic modifications to your Katana.

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Old 04-26-2011, 01:31 PM   #1
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Default Coil clips, how to deal

I doubt anyone will read this before messing with the wires, but here goes anyway..

While there is a serious design flaw on these coils, it isn't insurmountable..

Small thin bladed screwdriver.
Needle nose pliers.
Shear type wire cutters. (not dikes..) This is if you are reusing the wires

As you see from this drawing there is a wedge shape with barbs that crimps into the wire insulation. The force of the wedge is enough to keep the wire in place, the clips are just additional.


First wait until your wife/girlfriend is out of the house then steal the hair dryer..

Remove the coils and wires from the bike in one piece. Set them on a comfortable work surface.

Use the hair dryer to warm up the clips in an attempt to soften them.
Carefully work the clips with the small screwdriver easing them off the barbs. Stop there.

Use the wire not the clip to pull the wire and clip assembly free from the coil.

Now ease the wedge off the wire. As you will see the barb indented the insulation.

Measure the distance from the end of the wire to the crimp. (A)

Shear off the end of the wire.
Make a mark from the new end to the distance you measured.
Position the clip assembly at the mark.

Use the needle nose pliers to carefully push the wedge into the wire to pre-indent the wire. You ought to be able to get the wedge set all the way into the insulation.

Repeat for the second wire.

You should now be able to insert the wires into the coil almost all the way.
Push on the edge of the wedge with the thin screwdriver until either the clips grab or based on the parts left (from where the clip broke) the wedge is pushed in fully.

I have run with broken clips for a number of years and the wires stay in the coil just fine.
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