Hello, on my ignition coils, it looks like the plug wire is hard wired into the coil. Is there anyway to replace the plug wire without replacing the whole coil?
'85 Virago 700
Newbie - Ignition coils
If the plug wire is cut up you can cover it with heat shrink tubing, Check the voltage going to the coil should be the same as battery voltage, check the electrical connections and the ground wire, clean and tight. Just trying to save you money I know if you buy a new one from a dealer its going to be expensive. It could be a bad connection, battery low or bad, or your bike is putting out a low charging rate. Is the bike hard to start, running bad you think its from a weak spark? It could be the coil and the wire is ok, but ur not getting enough voltage to power the coil.
2011 Toyota Tacoma 4x4, 09 Yamaha Tmax, 08 Suzuki King Quad 750
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BuzZz
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You can actually replace the lead.
It will be glued into the coil, but you can break that seal if your determined. Inside the nipple of the coil where the wire goes, there is a pointed, threaded, metal post... the output from the coil. You must get this post into the new lead's wire core(don't use carbon core wires) and turn the lead to screw the post into the wire. You should also put a little epoxy or silicon around the end of the lead before you thread it into the coil, but careful not get it on or into the center wire of the lead. Let it harden/set-up before messing with it and re-installing the coil.
Take your time and do a nice job.
It will be glued into the coil, but you can break that seal if your determined. Inside the nipple of the coil where the wire goes, there is a pointed, threaded, metal post... the output from the coil. You must get this post into the new lead's wire core(don't use carbon core wires) and turn the lead to screw the post into the wire. You should also put a little epoxy or silicon around the end of the lead before you thread it into the coil, but careful not get it on or into the center wire of the lead. Let it harden/set-up before messing with it and re-installing the coil.
Take your time and do a nice job.
No Witnesses.... 
OK, I got it out the (very) hard way. I've since replaced the wire and *glued* it shut with seal all becuase I had to break part of the housing to get the whole thing out 
That'll make it easier to replace in the future (or cost me $70 to buy a new one. Anyway, it's running the same as it was before, which is good and bad.
BTW, has anyone used a different coil rated at a different resistance for a bike? I'm wondering if, in the future, I could do that without possibly frying anything.
That'll make it easier to replace in the future (or cost me $70 to buy a new one. Anyway, it's running the same as it was before, which is good and bad. BTW, has anyone used a different coil rated at a different resistance for a bike? I'm wondering if, in the future, I could do that without possibly frying anything.
If your coils are like mine were, you actually Can put new wires on em, it does work, its just a huge pain in the "O Ring".
I wound up replacing my coils eventually, in the meantime what i had to do was strip the boots from the old wires, trim an inch or so from the ends, and force the erm, very aggressive male plug into the wire itself. serious grunting and groaning there to make sure it was a good fit, snugged the rubber boot back over where the plug and the wire met, and used superglue all around to keep em sealed.
on the coils themselves the erm. penetrating part was much slimmer and easier to push into the wire, but more delicate too, gotta use straight line force there. again, superglue around where the wire went in to seal it up good.
make sure you label which wire goes to what cyl.
I wound up replacing my coils eventually, in the meantime what i had to do was strip the boots from the old wires, trim an inch or so from the ends, and force the erm, very aggressive male plug into the wire itself. serious grunting and groaning there to make sure it was a good fit, snugged the rubber boot back over where the plug and the wire met, and used superglue all around to keep em sealed.
on the coils themselves the erm. penetrating part was much slimmer and easier to push into the wire, but more delicate too, gotta use straight line force there. again, superglue around where the wire went in to seal it up good.
make sure you label which wire goes to what cyl.