GL1200 Pulser coil mounting improvement?

Hi all,

With help from this great forum I'm 99% certain the pulser coils have failed in the classic way (high temperature cut out). The bike is an 84 1200 Aspencade with an 85 Interstate engine, coils at the front. I've been lucky and found some new coils, but now thinking of a way of mounting them to reduce the heating so that they last more than another 30 years - well, at least just be more reliable anyway!

I'm thinking about some form of insulation below and above the mounting plate, between casing and bolt head. I'd like to use rubber washers, but don't trust them to stay in place. Reckon I'll be using some bolt locking fluid as I may not be able to nip the bolts up as tight as they should be. I'm also reckoning the slight mis-positioning (0.5 - 1.0 mm) shouldn't upset the timing.

An alternative may be to drill some small cooling holes in the covers to get more airflow round there. Anyone done that? Have to be clever with positioning and muck filtering.

What do you reckon? Waste of time? Good idea? Risky? We're off for a tour of Europe in a couple of weeks and don't want these failing again.

And just an associated query - has anyone been inside these coils to see what fails? I'm guessing either a dissimilar metal connection corroding, or a solder connection melting/going 'dry'. If nobody has, I'll try and do an autopsy when I get some time.

Thanks,

Ian (UK based)


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