Join Date: Jan 2015
Location: A stone's throw from Luckenbach, TX
Year/Make/Model: 1996 Kawasaki Vulcan 800 Classic
Spark Plug Wires Went To Ground
1. While testing for spark, I noticed (luckily!) both spark plug wires jumped a spark to ground! Both caps had a small cut in the same place (across from the inside metal plug cap, I'm sure from bending all the time to get the cap in the hole). This could be why I was only getting weak orange sparks. Thoughts? (This could be what fried the CI Igniter.)
2. I went to order new plug caps, so I was going to order the wire too, but I'm not seeing them in any of the diagrams or parts list. Am I missing them, or do I just go to a parts house and get a random length of wire and make my own? NOTE: The PO put an aftermarket wire on one of the plugs (7mm) and it is too small; easily pulls out, and the cap on the coil that keeps it tight is useless because the diameter of the wire is too small. I bought an 8mm plug wire at parts house but it is too big. Seems I need a 7.5mm, which brings me back to: I can't find the wires anywhere in the diagrams. Do the wires come with the plug cap, maybe? Parts diagram shows the wire, but no part number.
Any advice/guidance would be appreciated. Parts house has a 7mm (too small) and an 8mm (too big). The OEM one on the other cylinder fits nicely.
1996 Vulcan 800, Blue/Green
JUST SOLD: 2016 Indian Scout, Black
SOLD LAST YEAR: 2006 Triumph Rocket III, Black
SOLD LAST YEAR: 1967 Honda 305 Dream, Black
"Going up the country . . . "
Last edited by texasgrape; 01-21-2018 at 07:25 PM.
Reason: More info.