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spark plug wires

Discussion in 'XJ Technical Chat' started by hbwb, Sep 22, 2012.

  1. hbwb

    hbwb Member

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    Looking at my coils it seems the plug wires are part of the coil. I would like to get new wires but do not think they come off like on some bikes. Are am I missing something?
     
  2. MN-Maxims

    MN-Maxims St. Paul Minnesota

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    You can change the wires however you need to cut the plastic back on the coil to do it. When put the new wires on you will have to epoxie up where you cut the plastic away.
    MN
     
  3. Ground-Hugger

    Ground-Hugger Member

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    Check with chacal I believe he has parts so you can splice a new cable onto the old ones with out cutting into the coil.
     
  4. MN-Maxims

    MN-Maxims St. Paul Minnesota

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    Yes there are cable " splicers " but they suck in my book. Just one more connection to deal with if you are having problems. The coil surgery method is ok but a new set of Dyna coils would be better if you want to spend some money. Len xj4ever has brackets and Dyna coils

    MN
     
  5. hbwb

    hbwb Member

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    I don't have money so new coils are out. I noticed one wire arcing where the cap screws on and was hoping I could just get new wires. I moved it and it ran a lot better but that is no permanent fix. Both my kaws the wires screw off the coils. Why couldn't yamaha be so simple?

    Splicing them did occur to me but I thought that was an iffy idea at best. Any pics of that coil cutaway?
     
  6. MercuryMan

    MercuryMan Active Member

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    Arcing is not terminal. You just need to re-insulate. A flexible heavy solid content paint or coating will do the trick. Yamaha was saving $ back in the day and found it easier to construct the coils this way as it saved metal.

    Depending on how much play you have now in your wires you can trim them back and reattach the cap. I wouldn't replace the coils unless they are bad, the wires can always be repaired. Although new coils are a nice upgrade.

    .....going up.....? :)
     
  7. MN-Maxims

    MN-Maxims St. Paul Minnesota

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    Do a search for coil wire replacement. There is a whole thread on the subject
     
  8. hbwb

    hbwb Member

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    I wish I had a couple extra sets of coils I could play with. They would not even have to be good ones but ones I could experiment with. I am thinking instead of cutting into the body (as some of those articles states) I could perhaps drill out the wire. Since the measurements for the metal post are given I could set my bit to drill just up to the posts and use a smaller bit to remove the additional wire around the post. Or maybe make a cutter to do that. Thinking I could use some tubing the right size and file teeth on the ends so in effect have a hollow drill bit to cut away the remaining plug wire.

    I think it could work and I could bore the very end of the hole a little bigger so I could epoxy the wires in place and keep it neat.

    So what do you all think?
     

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