Replacement Spark Wires and Caps/boots

Hey all, so this was something I was looking at last year after the crash when putting the bike back together - the spark wires and caps/boots appear to be original and one of them was arcing which I discovered when I touched the header while the bike was running, warming up. I had a parts bike at the time, so I swapped on a cap from that bike and rode it the rest of the season, but now that the move is complete and my garage is at least somewhat in order, I'm starting to address the punch list of items I want to take care of and new spark wires and boots was one of them. Electrical stuff has never been my strong suit, so I was hoping someone could point me at the correct leads and caps for my 1981 KZ750 LTD - I know I can get 7mm solid core bulk wire at NAPA but beyond that, I'm kind of confused with wires/plugs/caps being resisted or not and how the wires all go together, or if there are pre-assembled options that might be better? My preference would be to pick up parts locally but if someone has links to a setup that will work well for my ride that they wouldn't mind sharing, I'd appreciate it. If I remember correctly from searching the forum last year, the OE B8ES plugs were discontinued as well as the NGK OE replacement caps for some reason... help?

I used bulk 7mm plug wire on my zl600. Was unable to get the wire coverings off the old wires and could not find a source of new covers. The two options I found so far are 5/16" thin wall fuel line or heat shrink.
With a flat blade screwdriver, you can dissemble the plug boot. Unscrew the brass sparkplug fitting. Now dump out the 5K resistor and spring. Clean everything up and put back together.
If you still want new plug caps, this will let you know if you need 5K caps.
 

The wires unscrew from your existing coils and plug caps.

Remove them, then use some WD-40, and shoot under the outer lead protector tubes, and remove them.  Push a stiff wire between the tubes and spark plug lead to create a gap, for WD-40 flow, as needed, in order to get the tubes loose.

Purchase 7mm copper core spark plug lead wire, and cut to size.

Check your old spark plug caps for resistance.  They should be 5000 ohms each.  If significantly different from this, remove the resistor using a screwdriver, clean and check again.  If this doesn't work, replace the caps.  There are various aftermarket options.

Before installing the new spark plug leads, install the outer protector tubes onto your new leads.  Again, WD-40 inside the outer protector tubes allow them to slide on easily.

Regarding spark plugs, go find some NOS NGK B8ES plugs, or, easier to find, buy NGK W24ES or W24ESU spark plugs.  Do NOT buy resistor plugs, such as B8ESR plugs.  

P1010602 by nessism , on Flickr

So NAPA offers two different "bulk" wires -

  www.napaonline.com/en/p/BEL734803
www.napaonline.com/en/p/BEL734601

Is there any real difference between these? Which is what I'm looking for, as neither explicitly say "copper core" anywhere that I saw? Thank you and apologies for my ignorance on this 

You can buy "bulk" spark plug wire from a good automotive speed shop. They also usually sell the terminal ends and most of the different boots. If you don't have anybody local just go on the Jeg's or Summit web site.

I started to be interested in DIY spark plug wire sets as the ready to go motorcycle kits by Dyna and Taylor were getting too pricey.

I walked into a local "speed" shop and bought a Accell plug wire crimper and some bulk MSD wire. They also had Accell and Moroso brand wire as well, most of the wire is solid core specifically designed for racing purposes.

Lately I just buy any on sale quality brand V8 kit I can find and cut to length then reuse the terminal ends and boots if they are at the correct angle. The V8 kits are plenty long and you can get 2 sets for less than one set of a motorcycle specific kit. If the boots are wrong you can buy those separately.

bluejacobs wrote:

So NAPA offers two different "bulk" wires -

  www.napaonline.com/en/p/BEL734803
www.napaonline.com/en/p/BEL734601

Is there any real difference between these? Which is what I'm looking for, as neither explicitly say "copper core" anywhere that I saw? Thank you and apologies for my ignorance on this 

I don't think either of those wires are correct.  You want copper core, non suppressor wire.  I got mine at Z1, some time back.  I don't see the same wire currently on their site, but it's available in the markeplace.

Ton's Performance is a company selling bulk plug wire, caps, terminals, and other wiring accessories.  I found everything I needed to make up my plug wires.  Good quality parts and reasonable prices.  Get a few extra terminals and a some extra length on the wire to practice on.

sf4t7 wrote:

Ton's Performance is a company selling bulk plug wire, caps, terminals, and other wiring accessories.  I found everything I needed to make up my plug wires.  Good quality parts and reasonable prices.  Get a few extra terminals and a some extra length on the wire to practice on.

One of the nice things about the stock setup is you don't need any terminals or wire accessories.  The raw wires screw into the coils and plug caps.  

I am using TONs  also. I went retro with yellow wires and orange NR caps.  Ignition parts and accessories – Ton's Performance .

For anyone in Ontario, Canada I'd recommend Aircraft Spruce,  7mm copper core unshielded Rotax ignition wire

www.aircraftspruce.ca/catalog/eppages/spkplugwire.php

JR wrote:

For anyone in Ontario, Canada I'd recommend Aircraft Spruce,  7mm copper core unshielded Rotax ignition wire

www.aircraftspruce.ca/catalog/eppages/spkplugwire.php

Aircraft Spruce is also a good source of ACF50, a near-magical elixir.

Hey Saltroni, I made the yellow with orange plug caps also.  Like the Accel wire set I had on it in the 80's