How to fix spark plug wire

[Whoopbass]

The plug wire on a small 2 horse I have is missing the end that connects to the plug. The plug wire is built into the power pack so I don't want to replace the complete unit.
I tried shoving a wire into the end of it and attaching a connector from an auto plug wire I have but that didn't work. No spark at the end of the plug but I know it has spark because it shocked me.
It seems what I did was wrong or I didn't have it grounded good enough.
Is there a correct way to fix this?
Thanks

 

[Silvertip]

Re: How to fix spark plug wire

Yes! Marine plug wires have copper conductors so you need to bare a little bit that conductor so it can touch the metal plug connector. Crimp it on to the wire, replace the boot and you're done.

 

[jasper60103]

Re: How to fix spark plug wire

I believe you need something like this. Sierra makes one.

 

[Whoopbass]

Re: How to fix spark plug wire

I'm not sure but I think I already tried what you suggested.

At the end of the plug wire I could see a few strands of wires inside. I had some wire laying around so I stripped off the insulation wound up the copper strands tight and shoved the wire inside the spark plug wire about 1/2". The excess wire I wrapped around the edge of the plug wire and clamped the metal plug connector onto that. No spark.

I bought this outboard this way not knowing. The person who fixed this had a metal wire pushed through the middle of the plug wire about an inch in and then wound the excess wire tightly around the end of the spark plug. It worked but the problem with that is that it was impossible to remove the spark plug.

I'm going to go tinker with it again.
Thanks

 

[Dhadley]

Re: How to fix spark plug wire

Take a look at that same type kit fro BRP, it's a much better deal.

 

[Whoopbass]

Re: How to fix spark plug wire

I just got spark.
The problem I had was that I when I was pull starting it I wasn't pulling the cord out far enough. I had the wire in my hand trying to ground the spark plug, pulling the cord with the other hand while trying to hold the saw horse up with my knee.

Thanks for informing me on those repair kits since I think I will be needing one.

 

[jonesg]

Re: How to fix spark plug wire

I just got spark.
The problem I had was that I when I was pull starting it I wasn't pulling the cord out far enough. I had the wire in my hand trying to ground the spark plug, pulling the cord with the other hand while trying to hold the saw horse up with my knee.

Sounds like my workshop,
you can still choke the carb with a free elbow.

 

[mudslinging79]

Re: How to fix spark plug wire

ask around if anyone has a 50 gallon drum around, also check the local manufacturing companies. lots of times they get tossed out. cut the top off and you have an engine stand, fill it with water and turn the engine around so the prop is inside, and you have a test tank. no more trying to balance the horse with one hand, ground the plug with another, and pulling the cord with your teeth.

 

[tashasdaddy]

Re: How to fix spark plug wire

that's reason for using a spark tester.

 

[samo_ott]

Re: How to fix spark plug wire

Take a look at that same type kit fro BRP, it's a much better deal.

I agree. The BRP/OMC ones are great and only $4 or so. They usually solve my problems of old boots and questionable contact.

 

[speedcat2000]

Re: How to fix spark plug wire

Hey all, sorry to waken a dead thread, but better than starting a new one I guess.

I have bought replacement coils for my 1975 85 Johnson. They're Sierra parts, and come with the coil + spark plug wire as one unit, with the spark plug boot detatched.

Here's what I bought:
http://www.iboats.com/mall/partfinder/?*******=573764014&dz=[VE::Template%20can't%20find:%20dz]&gd_grid_id=1279&gd_partfinder=1&gd_poid=109175&gd_row=211&**********=978895178

As you can see, the boot come separate from the wire; and the wires are already attached to the coil itself. So what is that little metal spring for?

I can see a metal plug connector inside the rubber spark plug boot. I understand I'm supposed to crimp the spark plug wire to the metal plug connector inside the boot. Somehow. I'm just not sure how.

There's also a small metal spring with a little pointy metal end that comes out and then turns 90 degrees so it's parallel to the hole in the spring. I think this might be for crimping? Dunno. I saw a post here where they said this is for connecting the wire to the coil itself, however as you can see the wire is already connected to the coil.

I guess I'm supposed to bare some of this wire but since the metal plug connector is inside the boot already, how am I supposed to crimp this together?

Thanks!

 

[speedcat2000]

Re: How to fix spark plug wire

ok figured it out. I had to read that other post like 4 times, duh.

The little point is inserted into the middle of your spark plug wire, so that the point hits the conductor filament/wire in the middle of your spark plug wire. The "spring" hole, now attached to your spark plug wire, is inserted into the boot, so that the "spring hole" winds up inside the boot as it needs to connect to the spark plug itself.

I found that for 3 out of 4 of the boots, inserting the plug wire and spring jobby was "like a man having a baby" as someone else put it. My thumbs actually bled trying to get that f**** on there. The last boot, however, slid on like nothing. Seems Sierra (or whoever I ordered the ignition coils from) sent me different boots.

Thanks again!

 

[McGR]

Re: How to fix spark plug wire

A little silicone dilectric compound spread around the clip, end of wire and inside of the boot usually helps gettin those clips slid in there.

 

[speedcat2000]

Re: How to fix spark plug wire

Thanks McGR, I was thinking that too, but was being stubborn and did not want to go back to the store!

On to re-testing the spark. Wish me luck.