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spark plug leads
- Jimbo68
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03 Mar 2023 05:54 - 03 Mar 2023 05:55 #881013
by Jimbo68
1981 Kawasaki KZ440-A2
spark plug leads was created by Jimbo68
When I replaced my spark plugs I discovered my spark plug end-cable caps do not accept the usual spark plug ends. I had to unscrew and remove the top of the spark plugs. Thus, the connection is not perfect, though it seems to be adequate (the LHS is looser than the RHS. I've included a picture looking into the end-cable cap and it's clear the extrusion to catch the spark plug end is not much at all).
This led to a bit more digging.
The end-cable spark plug caps attach to the HV cable by what appears to be a bit of a bodge: the cap is pushed into the insulation of the cable, where it makes its connection to the copper.
Researching further, I don't think my spark plug caps are original. They are brown, and from what I can make out on the photo on the front of my service manual (I've included a zoomed-in picture of that here), they would have been black when the bike was originally built. That might explain why the caps don't fit the spark plug tops.
My questions for you please are:
My bike is a 1981 KZ440-A2 (as far as I can tell) Frame No KZ440A-026673.
This led to a bit more digging.
The end-cable spark plug caps attach to the HV cable by what appears to be a bit of a bodge: the cap is pushed into the insulation of the cable, where it makes its connection to the copper.
Researching further, I don't think my spark plug caps are original. They are brown, and from what I can make out on the photo on the front of my service manual (I've included a zoomed-in picture of that here), they would have been black when the bike was originally built. That might explain why the caps don't fit the spark plug tops.
My questions for you please are:
- Are my spark plug end-cable caps non-original?
- If so, does anyone know where to get the correct end-cable caps that will fit the spark plugs properly? I've tried eBay - all US so expensive postage.
- Is the means of attachment to the HV cable a bodge?
- If so, Can I replace the cables without a complete replacement of the starter motor?
My bike is a 1981 KZ440-A2 (as far as I can tell) Frame No KZ440A-026673.
1981 Kawasaki KZ440-A2
Last edit: 03 Mar 2023 05:55 by Jimbo68. Reason: Check box for notifications
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- Wookie58
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03 Mar 2023 06:15 - 03 Mar 2023 06:21 #881017
by Wookie58
Replied by Wookie58 on topic spark plug leads
The reason that spark plugs have the screw on caps is that different manufacturers of plug caps have different preferences (it's not a bodge)
Brown caps are normally NGK replacements for the originals
The cap having a threaded spike which screws into the end of the HT lead is also a normal method of fitment (not a bodge) if there was a poor connection here, with 20kv jumping across there would be significant signs of burning
Not sure how this relates to the "starter motor"
Brown caps are normally NGK replacements for the originals
The cap having a threaded spike which screws into the end of the HT lead is also a normal method of fitment (not a bodge) if there was a poor connection here, with 20kv jumping across there would be significant signs of burning
Not sure how this relates to the "starter motor"
Last edit: 03 Mar 2023 06:21 by Wookie58.
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- Jimbo68
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03 Mar 2023 06:20 #881018
by Jimbo68
1981 Kawasaki KZ440-A2
Replied by Jimbo68 on topic spark plug leads
Thank you for the prompt reply.
I meant ignition coil.
I meant ignition coil.
1981 Kawasaki KZ440-A2
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03 Mar 2023 06:22 #881019
by Wookie58
Replied by Wookie58 on topic spark plug leads
Unless you have a problem there is no need to replace the leads or the coils (they don't look in bad shape from the pictures)
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- Jimbo68
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03 Mar 2023 06:28 #881021
by Jimbo68
1981 Kawasaki KZ440-A2
Replied by Jimbo68 on topic spark plug leads
I was going to replace it only to get ones that snap-on to the out the box spark plug, with its cap on. Particularly given the LHS seems loose. I found these: NGK LB05F Resistor Spark Plug Cap
amzn.eu/d/jeomUbN
1981 Kawasaki KZ440-A2
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- Mikaw
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03 Mar 2023 06:35 #881022
by Mikaw
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.
Replied by Mikaw on topic spark plug leads
Your missing (or not captured in the photo) two HT rubber caps, they are shown in the parts fishe you posted as numbers 92071 & 92071A. The fit of the plug cap to both the HT wire and plug will be greatly increased with these two item and will seem less (bodge) what ever that is.
“Whatever boomer”
“Whatever boomer”
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.
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- Jimbo68
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03 Mar 2023 06:50 #881025
by Jimbo68
1981 Kawasaki KZ440-A2
Replied by Jimbo68 on topic spark plug leads
1981 Kawasaki KZ440-A2
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03 Mar 2023 06:56 #881026
by Wookie58
Replied by Wookie58 on topic spark plug leads
Yes, the Amazon item is complete, only fit resistor caps if your leads and plugs don't have resistors92071a I do have.
I don’t have 92071. I think amzn.eu/d/jeomUbN has that included. Would you agree?
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03 Mar 2023 06:56 #881027
by Mikaw
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.
Replied by Mikaw on topic spark plug leads
Yes, the replacement you posted has both item. They will dramatically increase the fit/function of the cap.92071a I do have.
I don’t have 92071. I think amzn.eu/d/jeomUbN has that included. Would you agree?
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.
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- Nessism
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03 Mar 2023 07:03 #881031
by Nessism
Replied by Nessism on topic spark plug leads
7mm copper core wire is what Kawasaki used. If you shoot some WD-40 under the wire outer protector, you can then pull it off and install it over your new wires.
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- Jimbo68
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03 Mar 2023 07:13 #881034
by Jimbo68
1981 Kawasaki KZ440-A2
Replied by Jimbo68 on topic spark plug leads
Thanks.
I have NGK B7ES plugs. I think they contain resistors.
I don’t know about the cables?
I have NGK B7ES plugs. I think they contain resistors.
I don’t know about the cables?
1981 Kawasaki KZ440-A2
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03 Mar 2023 07:39 - 03 Mar 2023 07:42 #881036
by Warren3200gt
Replied by Warren3200gt on topic spark plug leads
B7ES do NOT have resistors.
BR7ES DO have resistors.
So if your plug caps have resistors you use B7ES plugs.
If your plug caps do NOT have resistors you can use either plug model.
HT cables do not have resistors.
BR7ES DO have resistors.
So if your plug caps have resistors you use B7ES plugs.
If your plug caps do NOT have resistors you can use either plug model.
HT cables do not have resistors.
Last edit: 03 Mar 2023 07:42 by Warren3200gt.
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