80s Suzuki DS80 rebuild has begun!

[xrocket21]

I did some digging around and couldn't find an aftermarket option. Give Rick's Motorsports Electronics a call and see if they'll do a repair/rewind if you don't want to try tackling the job yourself?

Custom Rewind in Alabama (guy had a stroke, so call and get his number than text him) or Baja designs but their customer service kinda sucks

Ok, thanks guys

We'll get this damn thing running!!!

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I did some digging around and couldn't find an aftermarket option. Give Rick's Motorsports Electronics a call and see if they'll do a repair/rewind if you don't want to try tackling the job yourself?

cliffs on doing in myself? How do I know how many tuns it is, just count em? what about gauge?

[Kurlon]

cliffs on doing in myself? How do I know how many tuns it is, just count em? what about gauge?

Step one is an autopsy, slowly unwind it noting direction, turns, and size of wire. Get new wire, reverse the steps and wind it back on.

[xrocket21]

Ok, so I finally went and picked the bike back up today.

With my calipers I measure the diameter of the wire to be about 0.6mm, 0.021"

used this: https://www.convertunits.com/from/mils/to/mm

to convert the 0.6mm to 23.622 mils

This site:

https://www.flight-mechanic.com/wire...rical-systems/

shows 23 ga to be 22.6 mils and 22 ga to be 25.3 mils.

I figure including my wire is mot likely 23 ga.

BUT, I found this:

https://www.amazon.com/Remington-Ind...63&sr=8-5&th=1

with a 0.0221 diameter. but 24 ga.

This stuff is 23 ga, but double coated so its thicker

https://www.ebay.com/itm/Magnet-Wire...sAAOSw~CFY8BnP

Maybe I want double coated for a dirtbike application?

Thoughts?

[Kurlon]

I'd say go 24 ga, double coated. Not so much 'cause it's a dirty bike, instead thicker insulation just means less opportunities for nicks/handling during winding to cause issues with the final coil.

[xrocket21]

I'd say go 24 ga, double coated. Not so much 'cause it's a dirty bike, instead thicker insulation just means less opportunities for nicks/handling during winding to cause issues with the final coil.

Why do you say smaller 24 gauge wire?

[Kurlon]

It gets the OD closer to what you have now, winding count is more important than copper diameter for this application I believe.

[xrocket21]

It gets the OD closer to what you have now, winding count is more important than copper diameter for this application I believe.

Awesome, thanks man

Your order's in!
When your order is done processing, we'll email info
You should get it by Sat, Sep 19.

[xrocket21]

Spring is here, so yesterday I hand wound that secondary coil!!!! 400 turns!!!!!!


Still no spark.....





I think I'm gonna have to part it out on ebay

[xrocket21]

Old bump!

I sold the KDX to a friend and he got it running. I guess the parts from a 1 year newer CDI bike bolt right on so thats what he did and it has spark and fired up!

Second thing, now I'm trying to find bulbs for the DS80!