Welcome to the KatRiders.com forums.
You are currently viewing our boards as a guest which gives you limited access to view most discussions and access our other features. By joining our free community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join our community today!
If you have any problems with the registration process or your account login, please contact contact us.
|Katana How-To's & FAQ's A forum filled with write-ups, FAQ's, and visual aids for
mechanical & cosmetic modifications to your Katana.
||Thread Tools||Display Modes|
|04-26-2011, 02:31 PM||#1|
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.
|Thread||Thread Starter||Forum||Replies||Last Post|
|Plug wire clips||ProfessorHM||Wiring and Electrics||8||05-10-2011 12:18 AM|
|just some clips of riding||newjack76||Pics and Flicks||4||07-06-2009 07:56 PM|
|Fairing Clips||ontariokatana||Suzuki Katana Talk||4||06-24-2008 11:53 AM|
|LoCal Video Clips!||BearKat||Pics and Flicks||38||10-11-2006 04:53 AM|