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Help Spark plug caps difficulty removing - ZR250

Discussion in 'Kawasaki 250cc In-line 4's' started by Hubbo, Jun 29, 2015.

  1. Hubbo

    Hubbo Active Member

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    I must be doing something wrong, as I can't seem to remove the caps off the spark plugs (on my Balius ZR250 '91).

    The wires seem to just pull out leaving the caps still on the spark plugs. Surely this can't be right???! I've tried removing the caps - which seem to be a soft rubber over a hard plastic tube. Using pliers its just started breaking apart (see pics - including wire). Any ideas? Cheers.

    The wires look a bit iffy, so want to replace (or fix) these at least.

    IMG_3216.JPG IMG_3217.JPG IMG_3219.JPG
     
    Hubbo, Jun 29, 2015
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  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    GreyImport, Jun 29, 2015
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  3. thebeefsalad

    thebeefsalad Well-Known Member

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    What the... Did someone silicon the boots in place?
     
    thebeefsalad, Jun 30, 2015
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  4. Seapop

    Seapop Well-Known Member Premium Member Contributing Member

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    Ive been there done that mate..

    The spark plug caps on my Balius 1994 are orignially made by "Nichiwa" which got bought out by NGK a while back. I had a coolant filter/bottle leak and hot coolant spilt all over my number 4 spark plug cap which caused the rubber to get eaten away.

    I decided to take them out and replace it and this is where I ran into problems. The caps themselves should just clip on to the spark plugs inside and the lead should slide into the top of the caps which have a pin.

    Now here is the problem. Be very careful what new spark plug caps you put into there if you are replacing them...@GreyImport has correctly identified the spark plug caps that are SIMILAR to what you need but they are NOT what you need. Basically the ebay one linked will not fit into the cylinder and reach the spark plug. and also basically the SDO5FM DOES NOT HAVE THE REQUIRED RUBBER SEALING at the top of the plug cap to stop water and the likes getting into your cylinder and reaching your spark plug.

    What you really need is "SD05FMGC" please google it and have a look at the difference between this one and the SD05FM. If you can find a place to purchase these today, I will be grateful forever, because I have tried for a week searching for these to no avail...even contacted NGK and they are clueless about this type of plug cap.

    The originial part is a "Nichiwa SD05FMG" 5k Ohms. Good luck finding this also....as i believe Nichiwa doesnt exist anymore.
    The only real available one is the SD05F and the SD05FM which doesnt fit and doesnt provide the right sealing respectively..

    As for the reason your plug caps are breaking at the top I would say its most likely worn rubber, if you think about it the rubber is exposed to several elements and being from 1991...I dont like its chances. After 4 rides on my bike the rubber basically got eaten away by the coolant. So I dont know what you can do? Try pliers, try this and that...But be careful about what plug caps you replace them with.

    Please add any ideas to this guys because im still left with no decent plug caps to replace my old shietty ones with!
     
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    Seapop, Jun 30, 2015
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  5. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    GreyImport, Jun 30, 2015
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  6. Hubbo

    Hubbo Active Member

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    Ahhh perhaps I should have just left them on and replaced the wires. The wires seem to be coated in hard plastic and have bends - I'm thinking if I cut them they might not fit correctly.

    Thanks guys for the part numbers, that's a great help!

    Any ideas on part numbers for the leads or can I use any wires? (the caps seem to contain the resistors).
     
    Hubbo, Jun 30, 2015
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  7. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    They are usually 7 or 8mm and copper leads work just fine. You can buy it off the roll.
     
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    maelstrom, Jun 30, 2015
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  8. Seapop

    Seapop Well-Known Member Premium Member Contributing Member

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    I would cut a mm or two off the end of the leads to expose the wires a bit. Not a bad idea replacing the leads to be honest. I don't know much about them but I'm guessing they are pretty standard spark plug leads and can be found anywhere. Let me know how Yo u get on with the new caps.

    @GreyImport beauty exactly what I need. Now to translate to English and try contact them might be another story. Let alone shipping to new zealand.... Hmm I might be in for a rough ride with the new caps. I'm the same as you mate have used the non sealing sd05fm on the ones I replaced and try avoid the rain.

    Cheers team
     
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    Seapop, Jun 30, 2015
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  9. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Suggest to them to look after you and the Kawasaki owners on the forum will give them more business.
    Most countries offer a "Small Packet" or "Small Parcel" option for mail. Choose that one and registered and you will not have any worries.
    cheers
    Blair
     
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    maelstrom, Jun 30, 2015
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  10. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    GreyImport, Jun 30, 2015
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  11. Seapop

    Seapop Well-Known Member Premium Member Contributing Member

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    @maelstrom and @GreyImport good idea and cheers will get in touch with them and let them know there's a couple of us battling with these caps.

    Also 7mm is correct for the leads. They do need a tight fit on the top of the caps so 8mm might or might not work. Just take your cap into a place that sells them and test it out if you can
     
    Seapop, Jun 30, 2015
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  12. Joker

    Joker See "about me" for contact details. Contributing Member

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    I thought these were pretty universal. Provided they are the right length and the right resistance... what more do you need...?

    If it doesn't "seal" then just get some rubber boots that fit? It's just to keep water out...?

    Or hit up a wreckers from findapart.com.au? someone with a bike lying around would surely have some?

    Maybe I'm just over simplifying it..?

    I've got a set of four bandit ones lying around... only 3 have rubbers but surely they're transferable if you just need the rubbers..?
     
    Joker, Jun 30, 2015
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  13. Seapop

    Seapop Well-Known Member Premium Member Contributing Member

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    I need the rubber seals at the top or basically I can't ride in the rain..... Not that I purposely intend on riding in the rain.

    Your right they are standard but they aren't as suitable as the originals for the zxr engine (same as balius). They don't fit nicely and snug they are much slimmer the only thing they are is the same resistance and internal design. The rest of them are useless for my balius.....

    Have thought of rubber boots but unsure where to find these or make some maybe? Pretty new to this kind of stuff so yeah.
     
    Seapop, Jun 30, 2015
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  14. Seapop

    Seapop Well-Known Member Premium Member Contributing Member

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    @Stu would love to see a pic of the bandit ones to see if i can maybe source them somehow.
     
    Seapop, Jun 30, 2015
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  15. Joker

    Joker See "about me" for contact details. Contributing Member

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    The bikes being wrecked so if you want them I can offer you a good price :)

    If you give me the dimensions of yours (width, length etc) I can see how they compare.

    Spark plug caps.jpg
     
    Joker, Jun 30, 2015
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  16. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    mine have the normal rubbers both ends , just not the big flappy end that is on the stock ones .... FZR has alot more open space there than the Kawas long deep holes

    IMGP2009.jpg caps.jpg
     
    GreyImport, Jun 30, 2015
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  17. Seapop

    Seapop Well-Known Member Premium Member Contributing Member

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    @Stu

    Funnily enough one of my plug caps has one of these rubber boots on them. The others are the originals which are very old and buggered.

    I'm interested in these. Wether it's buying them off you or finding the part numbers to source them myself.
     
    Seapop, Jul 1, 2015
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  18. Joker

    Joker See "about me" for contact details. Contributing Member

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    inbox me if you want them and we'll work it out. Not after much for them to be honest.
     
    Joker, Jul 1, 2015
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  19. PhilMeUp

    PhilMeUp Active Member

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    I just did some searching for this and found two sources:

    - Maxwell Motorsports - showing that part number for coils for a Honda TRX400EX
    https://www.maxwellmotorsports.com....97c7f789cb5ef22c&rowstart=669&productlimit=51

    - An eBay listing for a “84-87 Honda XL250 XL250R XL350 XL350R Ignition Coil Assembly”

    This was removed from a 1984 Honda XL250R, but will also fit:

    1984-87 Honda XL250R
    1984-85 Honda XL350R

    Honda OEM Part Number: 30510-KG0-003

    Up for sale is a Honda XL250R Ignition Coil. It is from a 12 volt system. The coil is stamped MP02 4124 and Nichiwa SD05FMGC on the boot.

    http://www.ebay.com.au/itm/84-87-Ho...0-XL350R-Ignition-Coil-Assembly-/171819281706
     
    PhilMeUp, May 5, 2016
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  20. Adam Giles

    Adam Giles Well-Known Member

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    Have a look at megazip. I got originals for my zxr250.

    Sent from my HTC Desire 620 using Tapatalk
     
    Adam Giles, Jul 8, 2016
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