spark plug wires

Any way to change the spark plug wires on a stock 650 maxim?
I know I can change the caps, looking at the wires where it goes in the coil looks kind of scary, does it come out?

 

No.

There are two choices in this are:

1. Cut the coils open and replace the wires. There used to be a how-to for this at http://www.xs11.com/tips/repair/repair24.shtml, but that's a dead link now.

Anyway, this is basically using a Dremel to cut out the plastic over the ridge where the wire runs down the side of the coil body, then pull out the old wire, attach in a new one (solder?), and cover up with a bunch of silicone.

2. Alternately, and somewhat kludgier, most motocycle dealers who carry NGK, will carry their HV splicers, which can be used to splice a new wire to the old one near the coil body.

Cheers,
Paul

 

I have an 85 maxim 700 and have been successful pulling the wires out and putting new ones back in using a liberal amount of KY jelly or Astroglide, believe it or not. It took a while and required some twisting, but all four plugs seated well on the nail-like electrode inside the coil and no cutting was necessary. I don't know if you can do this with 650s, however. I would add that breaking one of the electrodes would really suck, obviously. I think if they are in those dire straights they would most likely break pulling upon removal.

Good luck.
Marshall

 

You're lucky to get the Wires out without doing some cutting on the Case.
Most of the Coils have Wires that look like the Casing was injection molded around the Wire.
The Wire is so tightly held by the form-fitted plastic that there isn't any way to get the Wire to move even a little bit.
Cutting through the case and prying the Wire loose is the only way!

Here's a look at where the Wire was surrounded in this Coil.
Note how the Case is formed by where the wire was removed:

 

hmm,, bad design on yamaha