I was in the process of changing the plugs on my '03 600 and noticed that the metal 'cap' within one of the plug boots broke off and remained on the spark plug tip. I saw in my parts manual that the plug boot is a separate part from the wire, and so I was able to unscrew the boot from the wire. I was thinking I could just order a new boot, but from checking the major OEM parts web sites I see that part has been updated and you have to order the boot w/ the wire attached. I got the new part and I tried to unscrew the boot, but it feels like its permanently attached. So now I'm thinking I'll need to replace the boot and wire. But now I can't tell how remove the existing wire that connects to the ignition controller. There's a boot that comes off, but the wire itself is still attached to the side of the controller. The wire on the new part is just a cut off wire.

Any one know how this connects? Thanks.

 

Nobody?

 

Well I don't know about these............But I do have some background with the plug wires on sleds!!

They have a steel threaded base that the wire will turn into (clockwise) and turn out counter clockwise. Some of the aftermarket plug caps would just turn on the cut end of the plug wire also!!!

These were given me trouble on some of my older sleds and would remove only to find the threaded screw type center would be rusted up and not making very good connection!!!!..

Hope that helps a little bit............So with the factory seal(wire and cap) on there it might not be removable????.........................Caper....... .........

 

I don't think the cap/boot is removable on the replacement OEM part...at least it doesn't appear to unscrew. So now I'm assuming I just have to replace the whole part up to where it connects to the ignition controller...and that's where I'm now running into problems as well. I can't tell how the existing wire connects into the controller. I've tried twisting and pulling, but no luck. This doesn't seem like it should be that difficult. I'd hate to have to bring it into the dealer for this, especially since I haven't had much luck with them.

 

Can't you just get a aftermarket spark plug boot that will screw into the wire that is still connected to the controller???............I know for sure you can get the spark plug boots that will turn in!!1

Do you have a terminal nut on the top of the spark plug or just the threads????

With the snowmobiles I order the NGK BR9ES with the Solid cap...This way they is No chance of that spark plug cap turning off the threads!!...Which happened to me a few times then the cap is stuck in the end of the plug wire!!!!.......Caper...........

 

I've only been able to find the 'new' plug wire with the boot attached. I searched most of the major online OEM parts suppliers and they all had this newer version of the part, not the original.

 

Be carefull with aftermarket boots. My Scrambler had a resister in the boot and it corroded and broke the steel in the boot as well and I had to buy a boot. If your boot has a resister make sure the replacement does too. Mine just twisted on.

 

Dennis Kirk should have just the cap???

I know here in Canada Royal distributing have them also, And Canadian Tire(Pep Boys down there I think)...............I replaced them on a couple sleds I had plus buddies I worked on!!.....Want me to try to find a link for you??...Caper........

 

Sure that would be great. Thanks!

 

The wire justs screws off. Pull the boot off and screw the wire out counterclockwise while pulling on the wire. The wire is screwed onto a barbed wire inside the coil and it also has a little bit of glue holding it.