Urban Express coil change challenge

Hey all. I had to pull the ignition coil out of my NU50. Getting the old one out wasn't too bad but putting the new one in presented some challenges. My hands are too big, especially to reach the front screw for installation. After thinking about it for a bit I decided I could make it a lot easier.

Put both screws in the new coil and then capture them by putting a small 1/8 or 3/16th o-ring on the threaded/upper end of the screw. Now feed the coil in from the back left side. Screws are in the coil ready to be turned in.

For the rear screw I substituted a socket-head (Allen) screw. This allows you to tighten it from below with a ball-headed Allen wrench. We all have those right? Buy some if you don't. You can just get enough angle to screw it in.

For the front screw I used a flange bolt. The built-in washer of the flange bolt lets you push the fastener up into the hole with a box end wrench. If you have a ratcheting box end wrench, it becomes total child's play at that point.

So M5 X 0.8 socket head in the back and flange bolt in the front. Easy peasy.

Re: Urban Express coil change challenge

Captain Janeway /

Love that idea of using the o rings to hold bolts/screws. I'll have to remember this for threading other things into tight spaces.

It hard getting that coil wiggled in even with my tint hands. Just an awkward angle. My workbench is my parking spot floor

Re: Urban Express coil change challenge

I do not envy your workshop conditions. That's got to make everything twice as hard.

I am grateful for the 750 square feet of heated, well-lit work space I have with benches, a monster vice, and many tools on acres of pegboard.

The tilting motorbike work stand is especially wonderful. Anything from an Express to a Gold Wing, you roll it on and the bench tilts back to level. Probably the best cheap thing I ever made out of 2x4s and plywood.

Re: Urban Express coil change challenge

Captain Janeway /

> Jeff Adams Wrote:

> -------------------------------------------------------

> I do not envy your workshop conditions. That's got to make everything

> twice as hard.

>

> I am grateful for the 750 square feet of heated, well-lit work space I

> have with benches, a monster vice, and many tools on acres of pegboard.

>

> The tilting motorbike work stand is especially wonderful. Anything from

> an Express to a Gold Wing, you roll it on and the bench tilts back to

> level. Probably the best cheap thing I ever made out of 2x4s and

> plywood.

Well, I'm jealous. My stand is a couple of milk crates, and I only use those when absolutely necessary. Don't know that we've ever met, but I'm about 4'10" so a bike is hard for me to manuever up by myself. Oh well. Stuff gets done.

This weekend need to replace a piston on one of them.

Re: Urban Express coil change challenge

Is it hard to pull the piston pin? Do they usually slide or do you need to use a puller?

Most of the two stroke dirt bikes I've worked on require the use of a pin puller, just too tight to push out by hand. Unless of course the motor is hammered to pulp. Then they pretty much fall out when you take off the clips.

I replaced the base gasket and head gasket on my NU50 recently. I was very surprised to find Honda still offers the long cylinder bolts and for super cheap money. I get a frequent flyer discount at my local Honda shop. I think I paid about $1 each for the four screws. The old ones were pretty rusty so I was not comfortable that I could get an accurate torque on 'em. Ran a tap through the holes to clean them up and used the new screws. Very satisfying.

Re: Urban Express coil change challenge

Captain Janeway /

pull the clips and it should push through fairly easily. I just start it with the needle nose I used to pull the clips then continue with something else (like the oiled up new pin you'll be putting in). Just hold that rod so you don't bend it. I'm sure you'll have something to work. A phillips head screwdriver is good if it's sticking

Keeping it stock? Good. They're pretty bulletproof that way. It's just mods that make them fussy but you can say that about all these bikes.

« Go to Topics — end of thread

Want to post in this forum? We'd love to have you join the discussion, but first:

Login or Create Account