DC1-1 Coils Upgrade instructions and Tips

[gltriker]

Where did you find those new, primary wire bullet connector terminals?

[cfairweather]

Cliff- I use a lot of those original type connectors when I restore wiring harnesses. You can order them from several places but I got this last batch from eBay. The wire is rated for this type of application.
Here are the links:
Connectors:
https://www.ebay.com/itm/283601470211
https://www.ebay.com/itm/224898601743?var=523767174391

Wire: https://www.ebay.com/itm/113148282074?var=413453603076

Screws:
https://www.ebay.com/itm/111998058244?var=410940302698
https://www.ebay.com/itm/174811165268?var=474299991251

[Sidecar Bob]

I think those are the same bullet connectors I have.
I don't need ring lugs very often so when I do I just use ones I get at an auto parts store.
I buy plain colour wire from Princess Auto (similar to Harbor Freight) for about half of that eBay listing's price (yes, I know prices are much higher than they were a few years ago).

I also keep the 2.8mm connector terminals and the connector blocks they go in (also bought on eBay) and the 0.25" terminals for the larger connectors (bought from Eastern Beaver a long time ago - I don't use very many of those).

As for the screws, the A2-70 bolts (commonly available metric stainless fasteners) and the F593C bolts (commonly available SAE stainless fasteners) all fall under the 18-8 category and therefore should be treated as equivalent to SAE Grade 2 (not suitable for any application with significant loads).
One has to wonder what grade of stainless the Chinese can sell so cheaply (usually less than they charge for zinc plated mild steel) and how soft it actually is......
Between those factors I will not replace any fasteners on my bikes with stainless unless I can increase by at least one size (e.g. I replaced the M6 bolts that attach the winter bike's fairing with 5/16 ones from a known supplier).

And having seen the effect of galvanic corrosion between stainless fasteners and aluminum parts I won't use them near anything aluminum again.

[Dr. Frankenstein]

The coils - those are the 'make-your-own' spark wire type, yes? What size...? 7mm?

And the boots - are you using the 135-degree ones, or the 180's? Any good sources for both the terminal ends and boots?

[gltriker]

The coils - those are the 'make-your-own' spark wire type, yes? What size...? 7mm?

And the boots - are you using the 135-degree ones, or the 180's? Any good sources for both the terminal ends and boots?

Dynatek sells 7mm spark plug wire along with their ignition coils. (Very Expensive and pitifully few strands of copper wire inside.)
Obtain 7mm copper stranded spark plug wire and crimp-on, coil end wire terminals elsewhere.
I bought a 4 cylinder universal set of build 'em yourself spark plug wires from NAPA.
note: If you utilize the generic ignition wire spark plug end rubber boot, you need a NGK spark plug terminal thread-on nut, too. Those same special thread-on nuts are typically discovered to become loose on the spark plug's top stud when you pull the plug wires off.
tip! you will not find these terminal nuts, individually, at an auto parts store
-
NGK Spark Plug Terminal Nut (145-48)
same nut different brand- DENSO
https://www.densoproducts.com/denso-067 ... rminal-nut

20220618_132356 SPARK PLUG TERMINAL NUTS.jpg (40.46 KiB) Viewed 2833 times

The NGK spark plug caps are identified as XD05F. (102 degrees angle for a GL1000 )
You may have better luck calling around to your local auto parts looking for NGK 's part number, 8072.

NAPA has them listed in their parts system as Part #: NGW 8072. Yes. NGW 8072.
Surprisingly inexpensive buying the XD05F NGK caps, locally. Your local auto parts store/s may not have them in stock, though.
Don't pay 'special order' prices.
Call around to other businesses, too.

[Dr. Frankenstein]

cfairweather, with those new coils, I'm assuming you also had to build your own spark wires - what spark wire terminal endcaps did you use, and do they fit well? I've found the Lucas type are too loose, and the banded steel ones are too big! What type are you using?

[cfairweather]

I have used a generic kit from 4into1 and it worked fine.
https://4into1.com/spark-plug-wire-kit- ... gna-coils/

I also went to NAPA and bought 7mm wire with ends and caps and these worked fine. Not sure the brand.

The Dyna DW200 wire kit works good too.

[Dr. Frankenstein]

Any idea where I can get JUST those silver terminal ends, and what they might be called? I've googled 'terminal ends,' 'spark wire terminals,' etc. and haven't found them anywhere else except on the 4into1 website, and only as a part of a kit; if they have them as part of a kit, someone somewhere must make them...

[gltriker]

Any idea where I can get JUST those silver terminal ends, and what they might be called? I've googled 'terminal ends,' 'spark wire terminals,' etc. and haven't found them anywhere else except on the 4into1 website, and only as a part of a kit; if they have them as part of a kit, someone somewhere must make them...

NAPA
Spark Plug Wire Terminal - Distributor

https://www.napaonline.com/en/search?te ... referer=v2

O'Reilly
Standard Ignition Primary Ignition Terminal

https://www.oreillyauto.com/detail/c/st ... ST26&pos=0

A reference source of spark plug related terminals
http://www.kingsbornewires.com/SearchRe ... p?Cat=1822

[gltriker]

The question of,
* how much of the air filter housing's inlet 'snorkle' original length might I have to remove to give the aftermarket right hand ignition coil and its upper sparkplug wire adequate clearance*, is answered here:

https://ngwclub.com/forum/viewtopic.php ... 56#p819956