TS185 pulser coil re-wound

**Rickthefix** · #1 28 Jan 2009

I was having issues with the ignition pulser coil in the magneto of my 77 TS185. Seems the coils were burnt. I unwound the coil, paying attention to the # winds & layers. Found some coated magnet/coil wire at radio shack that was of the same gauge. Rewound it and tested it 2 days ago, IT WORKED. All I have to do now is walk down to an industrial supply store down the street from work, buy some high-temp cloth tape, wrap the coil & then epoxy coat it.
I have a 80 TS185 parts bike & the pulser coil on it is bad as well, but the wire is a lot smaller gauge. The magnet/coil wire I bought came in a 3-pack, different sizes. It came with the correct size for the 80's coil, so I'll rewind it too & then try out the stator assembly on my 77. The connector for the CDI box is different & I've already mad adapter wires for it. The CDI box on the 80 is in pretty rough shape and has a split on one end of the metal case. It may or may not be any good. Only testing will tell. If anyone interested, I'll post some pic's on photobucket & post the link.

**Nigel Marx** · #2 28 Jan 2009

Well done Rick!
This is turning into the world resource for fixing TS185s. I hope Grant doesn't mind....

Was it easy to do? Is it worth posting how you did it or is it obvious? Maybe take some pictures of the process and photobucket them too.

Regards

Nigel in NZ

**Rickthefix** · #3 28 Jan 2009

Hey Nigel,
I did take a few picks of the beginning and end process of winding. Bought some high-temp masking tape today, will epoxy the coils & wrap with tape after it dries, then epoxy again over the tape. Will some pic's of the process & finished product.
The process would depend on which coil you have, just like my 77 TS185 pulser coil had a larger gauge wire than did the 80. This will make a difference in resistance readings since the smaller gauge wire takes many more turns and also has a higher resistance value per foot than larger gauge 77 wire. The finished 77 coil has a resistance of 1.5 ohms & not sure what the reading will be of the 80 coil when wound. There was about 33 feet of wire on the 77 coil, about 4 1/2 layers. I just started on one end, wound to the other end, reversed directions at each end. The 80 coil will take probably 10 times the # of layers and be much harder to get to layer correctly. Pretty sure they produced it on a machine.
But I'll give it a go after getting other stuff done to the 77. Replacing the clutch discs, both crank seals and kick start seal while I have the sides off.

Rickthefix

**Rickthefix** · #4 31 Jan 2009

Here's a link to some pic's of the coil rewind project:

TS185 77 Pulser Coil pictures by Rickthefix - Photobucket

I've now rewound the pulser coil for my 80 TS185 and have it coated with the Urethane. I just need to wrap it with tape and solder on the wire lugs. I'll try re-install it on the 80 stator plate and try it out soon & let you guys know how it works.

Should have the seals & clutch plates in before next weekend.

There's another forum for Suzuki 2-strokes, but not much traffic on there. Here's a link to it:

2-Stroke Motorcycle Forums -> 2-Stroke Motorcycles - Suzuki at AllThingsMoto.com

Later,