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Plug Wiring Short

bigtex

bigtex

Cruisin' Guzzisti
GT Contributor
Joined
Oct 27, 2008
Messages
223
Location
Northern Colorado, USA
I'm pretty sure this was covered by some of you pioneers, but I couldn't find the thread.

I picked up my bike from its first service, and it was a lovely 60 deg F day so I hit some of the fun parts shops, generally just taking the long way home. After stopping for about 20 minutes at Moto Gear Outlet (great place), I hopped back on Stella and it seemed someone had swapped motors with a Vespa. No power, terribly lumpy idle, and most tellingly, no heat in one of the headers. I limped back to the dealer (with just a couple of hours before closing time on a Saturday) and the tech found the right plug wire had a pinhole that was shorting to the head.

The hole was inside the right angle bend, a couple of millimeters up from the crook. Of course the parts department had no replacements but luckily they hadn't sold the black Stelvio yet, so they yanked its plug wire and sent me on my way.

So, didn't some of you run in to this before, and what were the underlying causes and fixes? Thanks all for the help.
 
Yup, known issue.

It's the wires and plug caps themselves. They are made of extremely soft material and are *sealed* into the tube by rings around them which make them air and watertight. The problem is that it also makes it very difficult to get them out without damaging 'em. Een iv you are very, very careful when prying 'em up it is almost obligatory for the rubber to rip just where yours has.

The result is that the spark shorts to earth on the rocker cover and the cylinder no-workee.

Mine are wogged up with silastic and masking tape which makes 'em more rigid and *Pryable* after it happend to me but my advice would be to try and get them out without damage ONCE and tie a loop of twine around the cap below the sealing rings. This can then be looped up over the top of the cap and hidden under the plug lead cover but next time the caps need to come off you can simply grab the twine and pull up gently removing the cap without having to go anywhere near the top of the cap.

Pete
 
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