Vehicles

650 - creating mount for gm coil

I recently installed a GM coil into the bike to replace a failed GIL unit that came with the boyer electronic ignition. I initially mounted the coil with zip strips but that was a temporary solution.

The problem with the GM coil is that it is too width to be mounted width wise above the engine as it will contact the gas tank when reinstalled. The coil has to be mounted lengthwise on its side. The next problem is that it is longer than the factory coil on an 81 xs650 which means the original coil mounting studs are now in the way of mounting the new coil.

I had to cut off one of the studs to make room. I then got some sheet steal and beat it into shape. One end was secured to the remaining coil mounting stud. The other end was secured to the frame using a U bolt.

All in all the coil is now very secure. It isn't going anywhere, though my bracket could be prettier. At least it fits under the gas tank without issue.

While I was working on the coil again I replaced the crimp on connectors I used originally in favor of some longer connectors I got from a household male electrical plug. A picture is worth 1000 words so scroll down to see what I am talking about. After some modification, these new connectors worked great and give a very solid connection.

Pictures

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2 existing coil mounting studs shown, may be different for non 81 years
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i cut front stuff off
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steel coil mounting plate ready for paint
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coated it to prevent rust
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electric plug I got my new ends from
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plug ends had to ground down to fit, bottom one fits, top has not been touched yet
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bracket painted
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coil mounted to bracket
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its very tight fit right by where the wire terminals come into the coil and the mounting stud is
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assembly mounted to bike frame, had to use a spacer on rear mounting stud to get coil centered
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connectors wrapped in several layers of tape, then foam applied to bracket just in case
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all done
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coil shown from other side, bracket attached to frame in front via U bolt

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