1986 Voyager XII plug wires

[smfick755]

I need to replace the plug wires on my 86 Voyager 1200 XII. Question I have is can you replace just the wires and boots without changing the coil packs. (are the wires removable from the packs or are they one unit.) And If so, what size and type of wires are best. I try to do all my own work but thought I should ask before I tear this down......thanks

[carl leo]

kawasaki does not offer the plug wires separately from the coils. i have found that Packard 440 from Nappa is a good replacement. you must use a wire core cable. do not use the silicone core wire..........

[bikerking.biz]

First, I'm wondering why you need to replace the plug wires, are they just mushroomed on the ends? If so, you should have enough slack to cut the mushroomed part off, and then screw the plug cap back on. If this has already been done, or you cut too much off, then you probably will have to replace them.

[smfick755]

I noticed when replacing plugs this year the wires had hardened and split. The boots were missing chunks and I had noticed a miss at idle and mid range cruise. I figured a new set of wires would help and just wondered which wires would be best. None of the shops in my area will touch it due to its age and I don't mind doing my own work.

[Mr Jensee]

The question was not answered on whether the plug wires can be removed from the coils. It would be helpful to others to know this ahead of tackling this project.

[carl leo]

sorry to miss this. the wires are replaceable, access to the coils however is difficult. i am seeing older machines with high mileage needing wires, i also replace the caps at the same time, the older caps tend to track and hardly ever Ohm correctly. the caps are expensive from kawasaki but the NGK replacements work very well, be sure to order the correct Ohm caps........

[richardb, austin]

I've done it. You can do it too. 4 ft of wire should be enough to do the job but measure what you've got. Although I didn't get them, I believe that the replacement caps are NGK SD05F Spark Plug Cap 8022 5k resistive plug cap for Kawasaki Voyager 1200.
Amazon had them for $2.76 + $1.95 shipping each as of aug 2, 2011. I've also got a half-vast tutorial that I wrote up. If you're interested, PM or email me.

[smfick755]

I appreciate all the great help. I will put it to use. I have been have been building bikes for awhile and have found sometimes it pays to get help from experienced people rather than just jumping in there and guessing. Thanks again and I will post pics of the completed project.

[richardb, austin]

Once removed, this is what the end of the plug wire that goes into the coil looked like on my bike

[99VoyagerXII]

Once removed, this is what the end of the plug wire that goes into the coil looked like on my bike

In place of the picture, I had a message saying that I didn't have permission to view the files! Can you post a photo, or at least describe what was shown? Thanks.....

[richardb, austin]

uhhh, Ron, why can't he see my pic? I posted a picture. It's a close up of that final segment of spark plug wire that fits into the coil. Shows the coil cap, a hard plastic ring that I named a cone ring because of its non-o ring shape and very thin, used I think, to seal the coil cap hole and then closer to the end, a more normal looking o-ring that's very thick. There was 11.5 mm of the end wire stuck into the coil with the thick o ring jammed up into the coil opening. This is hard to write - wish you could see the pic. But it's pretty straightforward in the removal - just don't lose or destroy any of these bits & pieces. I dabbed silicone on the fat rubber washer, not the coil cap, to better waterproof it.

[bikerking.biz]

uhhh, Ron, why can't he see my pic?

Where was the picture hosted? If in a personal picture account that you need a password to get into, that is probably why it is not showing up. You might need to host the picture in a public account like tinypic.

[suzib6sw]

If he is a member of the AVA, and is logged in , he should be able to see it..
If he is just a member of the Site, he wont be able to see the pic..
I think thats how it goes.. Ron will be able to confirm.