replacing lighting coil

400brian · Post by **400brian** » Wed Jan 30, 2008 3:03 am

I'm in the process of replacing the lighting coil on my '74 X8 ( 440/22 ).

The SM says to remove the stator plate, remove the lighting coil wires from the plastic plug, and pull the wires out of the protective sleeve, as you remove the coil. Then to reverse the proceedure to install the new coil.

Now, for that to work, the wires on the new coil would have to be full length and have the correct ends on them. It doesn't matter, as the wires on the new coil are about an inch long.

:o

So, I've got to splice it together. The wires are solid, not stranded. I figure soldering is the best method of splicing, but that leaves me with insulating the wires when I'm done. You have to be able to fold the wires up and tuck them behind the coil when installed.

Black electrical tape is not going to make it here. Anybody have any good ideas?

Danzig · Post by **Danzig** » Wed Jan 30, 2008 3:06 am

Heat shrink tubing, cut it to your desired length. Its the only way to go Brian.

JDFanPa · Post by **JDFanPa** » Wed Jan 30, 2008 3:16 am

I agree and double it up put a short peice over the joint and a longer peice over that

JDT · Post by **JDT** » Wed Jan 30, 2008 3:25 am

Yep, two layers will work best.

Make sure that the plate sits square on the case when you are reinstalling it.
Sometimes when you disturb the wiring from the way it layed in there originally it is hard to get everything back in a safe and secure position.

Do not overheat your soldering connection and burn off the varnish.

400brian · Post by **400brian** » Wed Jan 30, 2008 3:33 am

I'm aware of the heat shrink, but I've never used any. After it is shrunk, is it hard or flexible?

JDT · Post by **JDT** » Wed Jan 30, 2008 3:54 am

It flexes fine.

spitty · Post by **spitty** » Wed Jan 30, 2008 12:04 pm

When you buy your shrink tube ask for the product with the glue or sealant in it, seals off the repair, if you buy this product on price alone you will get what you pay for. My 2 cents. Spitty

JDT · Post by **JDT** » Wed Jan 30, 2008 12:08 pm

Very true Spitty. The 3M stuff is the best I have used.

400brian · Post by **400brian** » Fri Feb 01, 2008 5:59 am

Installed lighting coil tonight, pretty POed right now, still no lights.

Everything works if I hook the battery system up, but an ammeter shows it is discharging.

The coil I removed certainly looked like it might be bad, kinda overheated looking.

I don't see any way of testing the lighing coil in the SM, am I missing something?

JDT · Post by **JDT** » Fri Feb 01, 2008 11:30 am

Brian sent you a PM

Post by **WinnipegStPaul9** » Fri Feb 01, 2008 2:16 pm

Todd, have same issue with my Cyclone. Can you send whatever you sent to Brian? Don

harleysportster · Post by **harleysportster** » Fri Feb 01, 2008 6:41 pm

Don,
To test the lighting coil, unplug the main wiring harness from the sled to the engine and test the 2 top slots.
http://home.comcast.net/~psshd/CDI/lightingcoil1.jpg[/URL]

400brian · Post by **400brian** » Fri Feb 01, 2008 9:14 pm

Pat

Are you showing us a half an ohm?

I tested those two wires for voltage before I started, didn't have any. Haven't tried it since I installed the new coil, as it seemed obvious there wasn't any.
Will check there for voltage and resistance the next time I am working on it.

JDT · Post by **JDT** » Fri Feb 01, 2008 9:34 pm

It is possible to read the correct resistance as Pat has show us and still not have lights when you plug the connector back in and start the engine.

A short anywhere in the lighting wiring or a shorted Voltage Regulator will give these results.

Shorts on sleds are not easy to find as you can't just look for the smoke like on a car.

400brian · Post by **400brian** » Sat Feb 02, 2008 5:20 am

I'm thinking that if the Ohms don't look good, or if there is no voltage at the engine plug, then I have an issue right there at the stator plate.

If I do have voltage at the plug, then I have a wiring or V. reg issue.
What I don't know what to make of is the fact that everything seems to work fine on e-start battery voltage.