broken plug wire

[Hondaxrguy]

I just broke my plug wire on my XR400. The wire came out from inside the long boot. I'm wondering if the plug wires are special parts. Meaning, will any plug wire (as long as it fits) work? Are there aftermarket ones or do I need to go with a stock one? Can one be picked up at an auto parts store if they have one the same length? Thanks for the help.

Jeremy

 

[DualSportr]

There are tricker ones available, like something nicely waterproofed from Moose or MS Racing. The price is still very inexpensive, so I've always gone with these when it comes time for replacement.

 

[ochster]

Are you sure it's broke? You know that the coil lead actually screws into the "long" plug cap? If you take a light and look into the end of the plug cap, you will see what looks like the end of a machine screw, that the wire screws over. To install the wire you have to remove the black retainer in the top of the "long" plug boot. slide it over the coil wire and install the wire on to the screw threads. There will be 5 or 6 coarse wires in the lead, try to seperate them equally and center the screw, then slide the retainer back into place. I like to use a little dialectric grease for assembly on the componets.

 

[Hondaxrguy]

Well, I looked harder at it last night after posting. I can't tell if it's truely broken or not. I tried shining a light down there, but it's difficult to see. The end of the wire kinda looks like a clean cut, except for the center of the wire, where it looks ripped. There are no wires sticking out from there. I stuck the wire back in there, and I get a spark now. But, I don't know how well it'll hold up to vibrations and stuff from riding.

Jeremy

 

[ochster]

Jeremy. unscrew the cap and cut a 1/4" off the coil lead. This will get you into fresh wire in the center, it is common for these wires to get pushed in and not make good contact. This is a common fault on a lot of bikes. I check every one I touch as a preventative maintenance.

The wires won't be actually sticking out beyond the sheath, only flush with the end when you cut.

 

[Hondaxrguy]

Thanks a lot for the help Ochster. I cut off about 1/4" and looked at it and the wire was pushed in. It ended up threading into the cap easily, and is working great. Now I have to try to do some jetting changes because I had to switch back to the stock pipe. I'm not looking forward to it.:(

Jeremy

 

[ochster]

Do you still have the stock carb. on the bike?

What mods have you peformed?