Suzuki T250 motorbike - Suzuki motorbike coil to HT cable connection

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Sat 4 Sep 2021 17:42
Suzuki T250 motorbike - Suzuki motorbike coil to HT cable connection - rustonboy

I posted this in the bikers section, but there does not seem to be much trafiic there, so thought I would try here too.

Please does anyone know whether the HT leads can be simply unscrewed from the coils on this bike. The old ones have been cut off halfway to the plug cap, so an extension will be needed if the original leads cannot be disconnected from the coils. Many thanks :-)

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Sun 5 Sep 2021 14:24
Suzuki T250 motorbike - Suzuki motorbike coil to HT cable connection - craig-pd130

Former GT380 owner here. No, the HT leads are sealed into the factory coils with a waterproofing resin.

To extend the HT leads, get some fresh copper-core HT leads. Then take a slim steel nail, cut the head off and sharpen the cut end. Push it halfway into the end of the lead from the coils, ensuring that the nail is in contact with the copper core.

Then push your new lead onto the exposed sharp end of the nail. Cover the join with heatshrink to waterproof it. Then you can cut the new lead to length.

I used to use NGK Iridium plugs and NGK non-resistor caps on the 380. The plugs never needed cleaning or regapping.

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Sun 5 Sep 2021 17:47
Suzuki T250 motorbike - Suzuki motorbike coil to HT cable connection - rustonboy

Many thanks for your reply and advice - greatly appreciated. It can be tempting to pull or twist a bit too hard on something that doesn't want to move! Thanks also for your suggestion regarding the extension. That bit of the bike rebuild can now move forwards :-)

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