Pickup Coil wire stuck

[petepumpkin]

Hi, I'm doing my pickup coil in my 99 and can't seem to pull the wire out (plug end) It's stuck in between the clutch and rest of the frame/ wire harness.. I have the bike on a stand at the moment. Anyone had this issue?
Thanks, Pete

[brianmac]

is that the wire from the cluthch cover, ? oh yeah, PIA, lift the bike hi enuf so you can can get your head under and see. there is one of those yanaha wire harness zip ties back there where it WILL hang up. if u can see it, its easier to get thru.

[petepumpkin]

is that the wire from the cluthch cover, ? oh yeah, PIA, lift the bike hi enuf so you can can get your head under and see. there is one of those yanaha wire harness zip ties back there where it WILL hang up. if u can see it, its easier to get thru.

It almost feels like its zip tied, Won't move either way. I'll have a look around the other side tomorrow. cheers

[Lug Nut]

Those factory zip ties are tough lol. You need a good set of snips to clip those off

[petepumpkin]

LOL what a flippin nightmare. For starts the 'cable tie' was metal and bolted down.. Why, I ask why lol. Then the phillips head screws inside.. another WTF. Anyhow some how with the help of vice grips etc and cutting the old coil out, somehow I managed to get all those screws out...

[petepumpkin]

For future reference....

[davej]

that looks like a hex head screw not Philips. Any screw that you find on the bike that looks like a Philips head is actually a JIS screwdriver not a Philips, They are just enough different to strip the head almost every time if a Philips is used.

Edit: I said hex head and really meant to say socket head sorry

[petepumpkin]

that looks like a hex head screw not Philips. Any screw that you find on the bike that looks like a Philips head is actually a JIS screwdriver not a Philips, They are just enough different to strip the head almost every time if a Philips is used.

Thanks for the info, yeah just looked it up and I did read that the Japanese use the JIS. I ended up buying ordinary looking 'hex' bolts and cut them to length. I'll post a photo tomorrow when I put it all back together.

[petepumpkin]

A few things issues I came across. - Don't use hex bolts on the pickup coil as a socket won't fit - rest seems fine (I even skipped one as I ran out of bolts). - The after market pickup coils have an extra wire hole in the grommet/s. After getting everything assembled and running for a few minutes, a heap of oil started coming out of the grommet area - literally spraying out where the wires come out. - I took everything apart (lucky gasket was still good - unlike original which required a razor blade to clean the surface) and this time slapped on a heap of RTV in between grommets etc - initially I just put a little bit on the gasket and grommet in that area. - Also another issue. I read that I needed to put some oil into the crankcase, so I undid the big hex bolt ontop of the crankcase and put a litre in (around the same amount that came out. Anyhow after running the bike for a minute or so I thought I needed more oil going by the dipstick. I put another 500ml in the top tank. Well for some reason after running the bike again for a few minutes I found that it was way overfilled (check with bike level on stand). I managed to pump about 500ml -1l out using a hand pump with a hose down the fill tube. So yeah not sure what happened there.. So I'm waiting for the RTV to do it's thing for an hour before I torque it all down. It also says on the tube that I need to wait 24hrs to cure before filling with liquids. Fingers crossed that I don't get any more leaks tomorrow...

[roadiemort]

R* has the most convoluted way of checking oil as it is a semi dry sump system. Why we all use the 4 quarts in method lol. I overfilled also when I first got my 07 lol.

[Druegeme]

to route the cable back in the frame, I found it best to use a stiff wire and push the cable in from below rather than fishing from the top.

What RTV are you using.. is it oil resistant? I used the Permatex grey motoseal and it seems to work perfectly.

[petepumpkin]

All good now, no more leaks, used Permatex hi temp gasket maker/rtv - it did say not for heads or petrol but iirc oil is ok. Went for a ride and got a scare from how heavy the front end felt. Hadn't ridden for a few months and recently lost my job due to mandates so I guess I'm a little weaker than I though lol