Topic: Plug Cap Meltdown ?

[Adam_F]

So I've been having some trouble with cylinder 1 firing properly (I have another thread on my carb endeavors).  Carbs check out, so I went to check on the plug caps.  Instead of unscrew number 1, I just removed 1 and 4 from the plugs to test that way.  I've removed my spark plugs a hundred times, but have never removed the plug caps.  When I took the cap off spark plug number 4, it totally fell off the wire (see pic below) and left this mess:



I read that the plug caps are supposed to "unscrew" from the wire, so I checked #3 to see what it looked like:



That's more what I expected it to look like.  The screw inside the plug cap of number 3 was clean and it screws on easily to the end of the wire bundle.  When I looked inside the cap of #4 it was all gunky as if the PO had wrapped that wire around the screw and glued it together:



I'm totally wiring challenged, so I'm curious if anyone could shed some light on what my plan of attack should be.  New caps, but should I clip that wire back on #4?  Am I going to need a whole new wire and/or coil?

Could this be related to my issues w cylinder 1?

Thanks!

[scottly]

Yes, a problem with the #4 plug cap could affect #1. Trim the wire back and screw on a new cap. Check the #2 cap as well.

[Bodi]

Yes, new caps. You need two straight NGK SD04FP ones and two VD05FP angle ones. These screw into the wire the same as the originals.
You should cut off the end 1/4" or so where the old ones screwed in so the new ones hit fresh core. The ruined #4 end can just be cut off if the cable is long enough after trimming. If it won't reach, try swapping 1 and 4 cables - the wires might be long enough to reach the "wrong way", it won't cause any ignition issues since 1 and 4 are from the same coil.
If the plug wires end up too short you need longer ones. These coils do not allow for replacing the wires (without some McGuyverizing of the coils, not easy and ends up looking like a POS). You can use NGK cable splicers and some new cable, get used coils somewhere with good wires, or get new coils. The popular new coil choice is Dyna 5 ohm dual output coils because they fit nicely in the stock coil mounts but there are other brands. Dyna coils use push-in connectors for the wires, much the same as automotive coils or distributors. Dyna also sells cable with molded-on coil connectors (a longish cable with two connectors, you cut it into two pieces and install the plug caps on the cut ends, for two plug cables each) but you will still need the NGK caps. You can buy the wire and connectors at auto parts stores too, wire core spark plug wire is not super common but is available. Standard coil connector work on the Dynas, other brands are mostly the same.

[TwoTired]

I agree with Bodi's advice.

Do you want to know why there is mush inside the wire?  It's caused by heat and corona of arcing between the wire core and the plug cap post.  They need a firm connection and should be screwed on tight.  If it won't go tight, you can get internal arcing and insulation mush.  FYI

[Adam_F]

Yes, new caps. You need two straight NGK SD04FP ones and two VD05FP angle ones. These screw into the wire the same as the originals.
You should cut off the end 1/4" or so where the old ones screwed in so the new ones hit fresh core. The ruined #4 end can just be cut off if the cable is long enough after trimming. If it won't reach, try swapping 1 and 4 cables - the wires might be long enough to reach the "wrong way", it won't cause any ignition issues since 1 and 4 are from the same coil.
If the plug wires end up too short you need longer ones. These coils do not allow for replacing the wires (without some McGuyverizing of the coils, not easy and ends up looking like a POS). You can use NGK cable splicers and some new cable, get used coils somewhere with good wires, or get new coils. The popular new coil choice is Dyna 5 ohm dual output coils because they fit nicely in the stock coil mounts but there are other brands. Dyna coils use push-in connectors for the wires, much the same as automotive coils or distributors. Dyna also sells cable with molded-on coil connectors (a longish cable with two connectors, you cut it into two pieces and install the plug caps on the cut ends, for two plug cables each) but you will still need the NGK caps. You can buy the wire and connectors at auto parts stores too, wire core spark plug wire is not super common but is available. Standard coil connector work on the Dynas, other brands are mostly the same.

Thanks for the great info Bodi.  I have been considering buying the Dyna coils, but I'm gonna try new caps first.  Just put in a lot of $ into the ol' gal.  That number 4 wire does look short, but maybe I can swap it with #1 as you suggested.  Thanks again!

I agree with Bodi's advice.

Do you want to know why there is mush inside the wire?  It's caused by heat and corona of arcing between the wire core and the plug cap post.  They need a firm connection and should be screwed on tight.  If it won't go tight, you can get internal arcing and insulation mush.  FYI

Thanks for that info TT.  Makes sense.  It looked like the wire was just wrapped around the screw inside the spark plug cap rather than properly trimmed and fitted.  Definitely was mushy and melted in there.

[HondaMan]

Yes, new caps. You need two straight NGK SD04FP ones and two VD05FP angle ones. These screw into the wire the same as the originals.
You should cut off the end 1/4" or so where the old ones screwed in so the new ones hit fresh core. The ruined #4 end can just be cut off if the cable is long enough after trimming. If it won't reach, try swapping 1 and 4 cables - the wires might be long enough to reach the "wrong way", it won't cause any ignition issues since 1 and 4 are from the same coil.
If the plug wires end up too short you need longer ones. These coils do not allow for replacing the wires (without some McGuyverizing of the coils, not easy and ends up looking like a POS). You can use NGK cable splicers and some new cable, get used coils somewhere with good wires, or get new coils. The popular new coil choice is Dyna 5 ohm dual output coils because they fit nicely in the stock coil mounts but there are other brands. Dyna coils use push-in connectors for the wires, much the same as automotive coils or distributors. Dyna also sells cable with molded-on coil connectors (a longish cable with two connectors, you cut it into two pieces and install the plug caps on the cut ends, for two plug cables each) but you will still need the NGK caps. You can buy the wire and connectors at auto parts stores too, wire core spark plug wire is not super common but is available. Standard coil connector work on the Dynas, other brands are mostly the same.

Thanks for the great info Bodi.  I have been considering buying the Dyna coils, but I'm gonna try new caps first.  Just put in a lot of $ into the ol' gal.  That number 4 wire does look short, but maybe I can swap it with #1 as you suggested.  Thanks again!

I agree with Bodi's advice.

Do you want to know why there is mush inside the wire?  It's caused by heat and corona of arcing between the wire core and the plug cap post.  They need a firm connection and should be screwed on tight.  If it won't go tight, you can get internal arcing and insulation mush.  FYI

Thanks for that info TT.  Makes sense.  It looked like the wire was just wrapped around the screw inside the spark plug cap rather than properly trimmed and fitted.  Definitely was mushy and melted in there.

I can suggest also the coils from PartsNmore: they fit perfectly and work well for a lot less $$.
Their resistance matches the OEM spec exactly for the Mid Fours, too.

[Adam_F]

Yes, new caps. You need two straight NGK SD04FP ones and two VD05FP angle ones. These screw into the wire the same as the originals.
You should cut off the end 1/4" or so where the old ones screwed in so the new ones hit fresh core. The ruined #4 end can just be cut off if the cable is long enough after trimming. If it won't reach, try swapping 1 and 4 cables - the wires might be long enough to reach the "wrong way", it won't cause any ignition issues since 1 and 4 are from the same coil.
If the plug wires end up too short you need longer ones. These coils do not allow for replacing the wires (without some McGuyverizing of the coils, not easy and ends up looking like a POS). You can use NGK cable splicers and some new cable, get used coils somewhere with good wires, or get new coils. The popular new coil choice is Dyna 5 ohm dual output coils because they fit nicely in the stock coil mounts but there are other brands. Dyna coils use push-in connectors for the wires, much the same as automotive coils or distributors. Dyna also sells cable with molded-on coil connectors (a longish cable with two connectors, you cut it into two pieces and install the plug caps on the cut ends, for two plug cables each) but you will still need the NGK caps. You can buy the wire and connectors at auto parts stores too, wire core spark plug wire is not super common but is available. Standard coil connector work on the Dynas, other brands are mostly the same.

Thanks for the great info Bodi.  I have been considering buying the Dyna coils, but I'm gonna try new caps first.  Just put in a lot of $ into the ol' gal.  That number 4 wire does look short, but maybe I can swap it with #1 as you suggested.  Thanks again!

I agree with Bodi's advice.

Do you want to know why there is mush inside the wire?  It's caused by heat and corona of arcing between the wire core and the plug cap post.  They need a firm connection and should be screwed on tight.  If it won't go tight, you can get internal arcing and insulation mush.  FYI

Thanks for that info TT.  Makes sense.  It looked like the wire was just wrapped around the screw inside the spark plug cap rather than properly trimmed and fitted.  Definitely was mushy and melted in there.

I can suggest also the coils from PartsNmore: they fit perfectly and work well for a lot less $$.
Their resistance matches the OEM spec exactly for the Mid Fours, too.

Ooooh!  Thanks HondaMan!  If you have a moment, would you be so kind as to send me a link?  I looked around on their site and was unable to find them. 

Thanks again!