How to; Boot and connector on coil wire

Cannon51 · Dec 1, 2007

I bought a new Husky a while back so I would not have to work on old saws but still hate to have something thats not running. I found a new coil for my Super Mini SL (like a SEZ with anti-vib and chain brake) and got it running but cannot get the plug boot on over the wire and connector.
Cannon

blsnelling · Dec 1, 2007

With the spring/connector off the wire, push the wire through the boot. If necessary, use needle nosed pliers to pull it through. Once it's through, poke the connector through the insulation, directly through the center of the wire. Then carefully pull the boot to the end of the wire. Stop before the spring/connector pulls down into the boot. Use a screwdriver or something to push the spring/connector into the boot. This will prevent you from pulling the boot off the wire again.

jack-the-ripper · Dec 1, 2007

Just did one 2 days ago. Slide the plug wire thru the boot first.(without the coil attached) Then insert the coil into the plug wire and pull the plug wire back until it seats in the boot.

Cannon51 · Dec 1, 2007

Thanks guys. I shoulda thought of that. Got it on and its running.
Cannon

Stihl #1 · Dec 1, 2007

cool tool for ignition leads

Sliding the lead through first works well, but another technician showed me some pliers he made, so I made a pair that works a little faster for me. Get a cheap pair from the dollar store that are not hardened, and modify as below.

Drill or grind out the area for the lead, then drill 2 holes through 1 of the jaws. Thread 1 of the holes, I used a 6-32 machine screw. Sharpen a piece of wire, stick it through the first hole to the right depth and wrap it around the screw, clip it off and tighten the screw. If the wire gets messed up just make a new one.
I use these to pre-punch the hole for the spring clip so it is dead center in the ignition wire, and so I don't poke holes in the tip of my finger trying to get it in.

See the next post for the rest.

Stihl #1 · Dec 1, 2007

Next I put some lubricant all over the wire and boot and use this pair of modified needle nose to seat the clip and hold it while inserting it into the boot.