I was just about to pull the trigger on ordering an IgniTech TCI when I saw this thread. I’ve been having problems with intermittent spark on cylinders 3 & 4 at low rpm to the point where she will only idle with the choke on. I never had spark problems before so I just recently pulled out my TCI and did all the resistance testing and connection cleaning. So far all the tests seem to be pointing at a bad TCI. When I was cleaning the connections, I couldn’t help noticing how easy the male ends of the quick connect was to clean, but there’s really no good way (that I can think of) to thoroughly clean or even tighten the female side. I have to believe after 28 years of engine heat and vibration, those connectors in there have to of loosened up a bit. I was also considering hard soldering all the quick connects. I replaced all the diodes and the transistors on my TCI, put it all back together and still have the same intermittent spark problem.
So here’s my idea. I noticed the male tangs on the TCI are almost an exact fit for a female disconnect (a crimp-on type wire terminal). I happened to have a box of fully insulated female disconnects so I decided to try them on for size, they fit perfect, nice and tight. See the attached picture. I’m thinking of cutting the two Yamaha quick disconnects off, soldering on about a 6” pigtail on each wire, insulating the solder connections with heat shrink, crimping on the fully insulated female disconnects, and connecting each one to the TCI individually. I would also want to do something similar to the quick connect that handles the pickup coils.
As I said before, I was just “thinking” about doing it. But after reading this thread, I may actually go for it.