Is there a fix for to short of spark plug wires?

hrc200x

Active Member
Other than buying a new or used coil with the correct length spark plug wire, is there a fix for lengthening the old one and making it look somewhat decent? Can the old wire be completely removed from the coil housing and a new wire installed from that point outward? What holds the wire into the coil? I bought a NGK plug wire splice kit, haven't installed it but like other wire splices I'm guessing its going to make a fat spot in the wire.
 

hrc200x

Active Member
Yep, ct70. Have you used spark plug wire splice kits before, if so does it leave a very large area where the splice is? The stock wire is very stiff, is that from age or how they came?
 

kirrbby

Well-Known Member
It's from age. If you hear them with a hairdryer they will soften up and you can reshape it before it cools.
The NGK splice kit that I've used has a mechanical splice. Big ugly and I think about 1½-2" long.
 

kirrbby

Well-Known Member
I think I've read where racerx has described how to make a soldered splice that can be covered by heat shrink for a undetectable repair...Especially if it ends up inside of the frame.
 

kirrbby

Well-Known Member
I think the he makes a short, neat, soldered splice in the copper wire...Yes the new wire must be copper core. Then covers it with a small piece of the insulation from the new wire, glued in, and covered by heat shrink tubing.

You could drill out the hole in the insulation a bit to better fit the splice.

Please take pics and post up a how-to when you do yours.
 
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69ST

Well-Known Member
In a word, "yes", both methods will give you a sound, functional, repair.

I've been running the same NGK twist-on splice for the past 14 years and north of 22,000 miles on my daily rider. It works as intended, no problems, and...is fugly.

The soldered splice method is better, imho. It's just more work and a little tricky around the edges. You have to leave enough exposed wire length so that the solder will flow, without melting the wire insulation. That means a good ~0.500" that has to be filled-in afterward. The inner core of the factory insulation you'll have to remove to expose the copper strands is a good base layer because it's rigid, ideal for a strain relief. The outer layer oftentimes will be too thick to reuse, the soldered splice is ~twice as thick as the individual copper conductor segments. All the matters, at this point, is getting enough polymer wrapped tightly around the inner layer to fill-in what remains of the gap and eliminate the stress riser that would otherwise exist. IOW, you're replacing the external structure so as to replicate the original, unbroken, lead length as it was pre-splice. My preference is self-fusing silicone tape. However, electrical tape is fine...you could even use silicone RTV, it sets-up firmly enough. The shrink tube is key; it seals the joint and gives structural bracing. It's also not highly visible.

There's nothing stopping anyone from adding a final layer of rubber hose or thick plastic sheathing to the exposed section of HT lead. Most of the early bikes came from Honda like this. Talk about having your cake and eating it...:)
 
I had a friend of mine who shaved the top of coil back starting about inch back from where wire goes in and cutting plastic away until he got to the post inside of coil where wire attached. Then ran new wire through the hole in front and soldered to post. Worked like a charm lol still works to this day and has been 18 years I'd say d1e180ea113e46840a243838e7f9a12c.jpg
 
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