Spark Plug Wires Went To Ground - Kawasaki Vulcan Forum : Vulcan Forums
 
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post #1 of 4 (permalink) Old 01-21-2018, 06:55 PM Thread Starter
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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

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Last edited by texasgrape; 01-21-2018 at 07:25 PM. Reason: More info.
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post #2 of 4 (permalink) Old 01-27-2018, 12:56 AM
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Modern wire at auto stores has built in resistance/suppression and won’t work. Go to a hotrod, vintage or high performance shop and get copper core wire. Comes in bulk and they can cut off what you need for a few bucks.
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post #3 of 4 (permalink) Old 01-30-2018, 01:41 PM
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my spark plug cap broke when removing the front, i pulled at the wrong place and it broke off, so next time i need to remove the spark plug cap i am going to be more gentle near the elbow where it can snap off

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post #4 of 4 (permalink) Old 02-06-2018, 08:55 AM Thread Starter
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Anyone know if there are any aftermarket spark plug boots out there? I can't find any except the expensive OEM ones. I have cuts in both; I have them reinforced by wrapping with electrical tape for now. Thanks.

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 . . . "
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