Sunday, 27 May 2012

I wanted to go over the ignition system to make sure everything was  tickety-boo. The HT leads looked pretty old, which means they could be 30 years old and in dire need of replacement. Unscrewing the plug caps revealed some fairly dark and corroded looking copper core. I just happened to have enough cloth covered vintage stylee HT lead left over from the ducati so off we went. As I'm sure you're all aware the HT lead usually screws onto a short screw on the coil. So I attempted to unscrew the HT lead. It was pretty stiff, but I just thought that was the corrosion and age hardened insulation, so I turned harder. And the lead came out. But rather than there being a screw visible to fit the new lead to, there's a deep hole that goes all the way to the back of the coil. And the end of the old lead showed that it had been soldered onto the coil terminal.

Well WTF Suzuki? I'd never seen this before so I had a quick Google, and it seems that yes, some Suzuki HT leads from the late 70's, 80'sand even later are not replaceable items, without replacing the whole coil. Why would they do that? Arseholes.
I'm not having that so I cut the coil through the HT hole and at the bottom there was a tab with the end of the old HT lead still soldered on. I have no idea how they managed to solder it on there, unless the coils body was molded around it. So I soldered the new HT leads copper core on there and sealed around it with some silicone sealant. I gapped the plug to the upper limit of the specified gap and a quick visual check turning the engine over showed a fat, bright spark. Lovely.


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