possible plug wire problem

[tschamp20]

first let me say hello again i havent been around for the last 6 months w/ the new baby and all.it feels good to be back.
all right heres the story, after the rebuild ive had a demon that i cant seem to shake w/ this motor. every time ive been out since the rebuild but once the motor has basically crapped out.seemed to me that it was dropping cylinders. literally everything ignition wise has been replaced w/ new.
so tonight i got a few minutes to tinker w/ it,and heres what i found. when i first started it it sounded like a 4 stroke. ive had this happen previously. so i shut it down. went and grabbed a pair of channelocks. i started it back up and pulled the number 1 plug wire,it wanted to stall,rehooked it up. removed number 3 same thing. heres where it gets interesting. when i went to pull number 2 as soon as the pliers grabbed the boot PRESTO! the motor came to life,went to number 4 PRESTO even more power.ran great.
as a side note coils 2 and 4 are sierra which i had to assemble. 1 and 3 are DMS which came preassembled.
so i reassembled 2 and 4 but what im wondering is there something i can do to assure a good connection between the spring and plug wire ie:epoxy or possible soldering the stranded wire to the spring?
any ideas?tricks?
sorry for the long post but ive got six months of stuff to say!

 

[tschamp20]

Re: possible plug wire problem

one more thing i can pull #1 and #3 with my bare hand,but #2 and #4 will get ya,ouch! whats with that?

 

[Evinrude Boater]

Re: possible plug wire problem

I found a problem wire in my motor by connecting an ohm meter and then twisting the wires around. I suspect you'll find poor continuity until you grab the cap with your pliers. Chances are you're pressing the wire against the cap spring.

 

[clemsonfor]

Re: possible plug wire problem

Yep, i hate those assemble serria coils i have one and one CDI that was pre assembled i will not buy the serria brand coil again for that reason, im not sure i had a loose wire but i thought that i was getting more shock to me and might have an arcing problem out of the serria, so i put back on the original wire to get rid of the pieced to geather wire. I just like the professionally pre assembled wire that CDI sends with its unit.

Its to me like if you have ever pieced togeather your auto plug wire its never right again and keeps pullin apartt and your constantly messing with it, just buy the quality ones and be done with it.



just my opinion

-Nate

 

[Molaker]

Re: possible plug wire problem

It's pretty obvious #2 & #4 do not have a good connection at the plug end of the wire. That would be the reason it zaps you on 2 & 4, but not 1 & 3. The high voltage is jumping to you instead of across the plug.

When you assembled those Sierra wires, did you use any lubricant? Can you actually see the wire clip in the boot and is it aligned properly so as to snap onto the plug? If you did not use lubricant (silicon grease or spray, WD-40 or even liquid soap) it is very difficult to force the wire clip to slip around the 90* bend in the boot and align properly. Then when you put the boot over the plug, it only feels like it seated.

 

[F_R]

Re: possible plug wire problem

You don't push the wire around the 90 degree bend. You put the spring on the wire, then poke it into the wire side of the boot (with a dab of oil, don't use soaps and other water solutions). But before all that, you should strip 1/4 insulation off the end of the wire and fray it out so that it touches the spring. That, plus making sure the spring point pierces the wire should give you good contact.

Personally, I never touch the wires bare-handed. I HATE getting zapped!!!!

 

[tschamp20]

Re: possible plug wire problem

thanks for the replies. just got some pix of the #2 arching bad. ill post them in a couple minutes.starting to track this down.
earlier i discovered that the #4 plug wasnt firing. definately had spark getting to it. i found this by pulling the plug wire and there was no change in rpm so i replaced it. retested w/ new plug and rpm dropped signifigently.not to mention the increase in performance. so thats one more thing off the list

 

[tschamp20]

Re: possible plug wire problem

the arc is coming out of the boot and hitting the body of the spark plug.so what causes this arching to happen? and more importantly what should i do to fix this? thanks for any input. safe to say itll jump a 7/16 gap,lol

 

[Molaker]

Re: possible plug wire problem

You don't push the wire around the 90 degree bend.

F_R, perhaps what I should have said is the spring coil in not always easy to get oriented correctly without lubricant.

 

[tschamp20]

Re: possible plug wire problem

i knew what you meant.thanks

 

[Silvertip]

Re: possible plug wire problem

I hate those rediculous OMC plug connectors. I've used NGK motorcycle style phenolic plug connectors (without a resistor). They grab the plug securely, have brass internals, and have an excellent moisture boot. If you can't find those without the resistor, the resistor can be removed. The non-resistor P/N = LZFH Stock No = 8381

 

[F_R]

Re: possible plug wire problem

I can't say what happened to make it arc out in the first place, but now that it has been arcing it probably wont stop till you replace the boot. The arcs burn a streak in the rubber and the burnt rubber acts like a conductor. Replace the boot and use dielectric grease to seal it.

 

[tschamp20]

Re: possible plug wire problem

hypothetical, not that i would want to, but what are the ill effects of leaving it as is. is it not allowing full power to reach the electrode of the plug?

 

[clemsonfor]

Re: possible plug wire problem

Reduced power and misses when not reaching the plug to fire it and more black gunk from unburned fuel in motor? Posible electrical failure maybe from prolonged arcing meaning it has lots of resistance to ground and cant find it easily. Not an expert though, id just go to dealer and get a new wire or buy a new coil set (not sierra, CDI maybe mine was cheaper than sierra from ebasicpower.com, but i ordered other stuff to dilute the cost and was still cheaper after shipping than iboats!) Use the new wire and keep the coil as a spare.
The dealer or repair yard may even have some parts motors around and let u get some wires for not much$.

-NAte