Ignition Assembly Question

[ZX7RJoe]

I recently had a problem where my '94 zx7 (L2) was only running on cylinders 2 and 4.Found the problem to be a bad spark wire connection somewhere between the boot and the coil,both 1 and 3 were the same issue.I was able to trim some wire off,reassemble each cable and get it running on all 4 cylinders again BUT...

My cyl.1 cap is snapped off a little at the top and my connection on wire 4 is questionable,not sure how long this will hold up.I want to replace all 4 wire and boot/cap assemblies to fix the problem correctly.However,to get new plug wires I need to order a whole new coil.I called the parts supplier (Kawasaki Parts Nation) and they said that the wires come with the ignition coil and can't be ordered on their own.

Anyone know any way around this,somewhere I can get just the wire?

Or is it recommended that you replace the coils when you replace wires?

I'd like to avoid dropping the $180 on new coils if I can,if it needs it though,I will.

[Geezer]

there is no reason a coil should have to be replaced if it is working properly, just because the wire is bad; wish i could say i was surprised they built them with the wire as an intergral unit. don't know how those are constructed, but if you can separate the wire from the coil and replace a new one w/o damaging the coil there's no reason not to try it. the big question is: are they molded into the coil or can you detach them by non-destructive dissassembly (e.g. screws, snaps, etc.)? if they are molded in you are probably stuck, cuz you just can't splice those wires; the voltage is too high to insulate a splice. fyi, coil and plug wires are historically infamous for failure and have for decades been a favorite source of revenue for the unscrupulous out there who make up expensive repairs (burnt valve, broken ring, blown head gasket) to correct a miss, then replace the wires for pocket change. you can buy the wire by the foot at an auto parts store.

[ZX7RJoe]

Originally Posted by Geezer

don't know how those are constructed, but if you can separate the wire from the coil and replace a new one w/o damaging the coil there's no reason not to try it. the big question is: are they molded into the coil or can you detach them by non-destructive dissassembly (e.g. screws, snaps, etc.)? if they are molded in you are probably stuck, cuz you just can't splice those wires; the voltage is too high to insulate a splice.

The wires attach to the coil with a plastic threaded cap of some sort,I've had mine off and back on already.Now that you mention it though,I think the wire might have some sort of flared section at the bottom where it plugs into the coil helping to push it in.I'll have to check again,if there's some way to do it I'd love to be able to just run to auto zone for some wire and be done with it.

[Geezer]

Originally Posted by ZX7RJoe

The wires attach to the coil with a plastic threaded cap of some sort,I've had mine off and back on already.Now that you mention it though,I think the wire might have some sort of flared section at the bottom where it plugs into the coil helping to push it in.I'll have to check again,if there's some way to do it I'd love to be able to just run to auto zone for some wire and be done with it.

if that flared section on the end of the wire is removable (e.g. a metal contactor that you can pull out of the wire, which is a typical type of connection), you should be able to make the change. at any rate, wire is cheap and you got nothing to lose by trying. hope it works out

[ZX7RJoe]

Originally Posted by Geezer

if that flared section on the end of the wire is removable (e.g. a metal contactor that you can pull out of the wire, which is a typical type of connection), you should be able to make the change. at any rate, wire is cheap and you got nothing to lose by trying. hope it works out

True,I'm thinking I might even be able to make a clip or fasten something onto a new piece of wire that would work for the job anyway...I guess that's the route I'll try to go for now,I wanna get these parts ordered.

[AZXRider]

That's true, the fish shows the coils & wires as one piece with a separate part number for the cap (plug boot) but I know you can replace the wires. Unscrew the cap from the coil and take the assembly to your local shop they can help you. The wires need to be pretty stiff and solid core, make sure the diameter is the same so they seal in the coil boots. If you need to replace the plug caps ND or NGK sells them separately.

[ZX7RJoe]

I ordered new plug caps last week,should be here this Wednesday.

I've been thinking about installing and aftermarket ignition kit this winter,anyone have any suggestion on brand?

I found this kit on Cycle Parts Nation:

http://www.aftermarketcyclepartsnati...zztidaa1391zz~

Not sure if it's right for my application yet,I have to contact the manufacturer.

Any tips or suggestions are welcome.