Melted plug wire? Desin flaw? - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 5 (permalink) Old 10-21-2009, 02:20 AM Thread Starter
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Melted plug wire? Desin flaw?

Sarted my bike in the dark tonight and noticed the forward spark plug wire throwin sparks to the throtle cable gaurd. Dont know how long its been going on caus i nomuly am on it when i start it and its normuly daylight out. Turns out the wire rests right on the cabel guard and had melted through it. I happend to have a roll of electical tape so i used that to git me home.

Im picking up some wires tommorow amd shud be able to fix it with my shop manual and some arcives from this site.

Just wondering if this is a general problem and how yall went about seperating the plug wire and throtle cable.

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post #2 of 5 (permalink) Old 10-21-2009, 09:53 AM
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Check this out. Look behind the air filter and see where the throttle cables run. The should be on the left (or aft) side of the air tunnel that connects the filter to the carbs. If they are routed forward (or the right side) of the tunnel, there won't be enough slack the the line and they'll rub on the spark plug boot. The spark plug wire needs to run on the outside of the wire too. It's easy to goof that up when putting the engine back in. It may help if you can post some pictures here, of how the cables and wires are routed.

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post #3 of 5 (permalink) Old 10-21-2009, 12:16 PM Thread Starter
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Picturs coming tonight after i git out of scool

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post #4 of 5 (permalink) Old 10-21-2009, 08:03 PM Thread Starter
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thanks ironman

you were right bout the throtle cables being looped roung. i didnt do it but i bought her used so theres no telin.


i didnt git to the picturs. but i did tearn in to the problem and found out that it is just the plug cap that melted. local bike shop will git a shipment on friday. i put the wire behind a coolant hose so that gave me some play for spacing and i think i will still lock wire the throtle cable back a little bit.


ill keep posten my progress. heck i still havent realy looked at the other wires to see thier condition.

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post #5 of 5 (permalink) Old 10-28-2009, 06:23 PM
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Mine had similar issue on that sparkplug wire. The electrical arc was because the rubber cap of the sparkplug cap was rotten (14 year will do that to rubber). So I replaced all the spark plug caps and their rubber boots and added some dielectric grease in the space behind the rubber boot.
No more sparking coming from the cap/wire.

Hope this helps

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