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My bike developed a misfire on one cylinder and since I had the valve cover off I figured I might have oil in a plug cup.
When I pulled the number 1 plug wire there was no "click" of connector coming off the top of the plug, so I tried to reseat it. Again no click, so I removed the plug wire for a closer look and poked a spare plug in and out a couple of times to verify and still no click.
I figured I was screwed for a $100 set of plug wires either way, so I decided cut off bottom end of the rubber boot and broke off the plastic shell of the underneath until I could get to the metal connector.
The connector itself is a metal tube with a slot sawn in it and a piece of spring wire in the slot to make contact with the threads on the top of the sparkplug.
What I found was that the spring wire was so badly eroded from arcing that it broke when I removed it.
After trying several wire types to replace the broken bit, I found that 20ga. galvanized soft-temper steel picture hanging wire worked perfectly.
The net result is that the bike is running quite happily and I can hold off buying new wires until later in the year. :-D
Jim
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