I have faught this for the past 3 weeks, and still have no sollution. If you pull the side plastic off the bike to get to the spark plugs, crank the engin, and rev it up for about 10 seconds, the spark plug boot rises about 1/4 inch. You can push the boot back down to snap back into place, and repeat the process. When the boot comes up, you can hear the arking and feel the lose of power to the bike. The same thing happens everytime. I have had to make something to hold down the boots in hope that it will keep connection so I can ride the bike. I took it to the dealer this past week. I dropped it off on Monday, and picked it up on Friday afternoon. I talked w/the tech for about 10mins about what was done to correct the problem. He said that he had replaced the boot? He said that the problem was fixed. I did not have time to do the once over at the dealer, so I got the chance this morning. Cold bike, fresh from the dealer from being fixed for the problem, rev the engin, and quess what! It is popped off again. Oh I did fail to mention that before I crancked it this morning, I had to push the boot back on, because I noticed it to appear to be off again! The tech swore that he test drove the bike yesterday, and that he did not see the problem any longer. What is even worse is, I typed out a 10 line paragraph describing the problem. Telling him how to recate the problem and everything.

Has anyone else had this problem as of yet, or could help on how I can fix the problem. This has really stumped me. I have done everything that I know to try. I have added some sillicon to the boot, and I have crimped the end of the wire a little tighter to try to make it grip harder. Did not help!

Thanks agin for your time.

 

Man thats crazy I have the 700 and have never had that happen is it just one wire doing it or both.You mite want to take the plug out and push it into the rubber boot so you can see if its snaping into place and how tight it is..

 

Never heard of this problem before. It almost sounds like you are getting a compression bypass somewhere around/at the plug. Have you tried changing that plug? Do yourself a favor and switch to NGK's, I have seen/heard to many horror strorys with the champions.

 

I agree, that is about the only thing that could force the spark plug boot up. That spark plug has to be leaking by internally somehow and causing pressure inside the boot to push it up. I have been building all types of engines for many years and have never seen this before but it is possible.

 

I went through 6 set of plugs before I took it to the dealer. I normaly wash my bike off before I put it up after riding. I orginaly thought that water may be getting around the boot, and once the enign got hot, the steam built up pressure, and was popping the boots off. Last week I got the bike out of storage, changed the spark plugs first thing, and carncked it. The only thing I did different is that I whatched the plug boot for a min or so while I was reving the engin. This is when I noticed the boot unsnapping with in seconds. This was with a cold, dry bike. I have tried some Bosh plugs, because the local auto stores did not have the same champion plugs to replace, and two different Ploaris delears did not have them in stock as well.

I agree with some of the things yall are saying. I too thought it was some kind of compression pushing the plug off. I just thought it maybe steam or something. I don't know. I am taking it back Monday, and see what the tech has to say about lieing to me.

Thanks for your help.

 

Well my bike is still at the shop. My dealer finaly got through to Polair this morning. They are haveing some problems with these bike's spark plug wire boots, and some kind of seal? They told my dealer to try another boot, and they told them to change to a different pulg. Hopfully they went to an NGK plug. I will find out more tomorrow when I pick the bike back up. Just giving yall some things I found out today. They said once they get a handle on what is causing it, they will post a serivce report on this.

Thanks for your help........

 

I had this problem with my 700 last summer. Would pop off while riding. The electrode broke loose in the boot....15 miles back from camp. Fixed it with a stick and zip tie, but that's another story. Dealer put on a new wire and it is fine.

SpruceDeuce

 

Well here is the result of what was done. I picked my bike up today, and the tech said that he changed the spark plugs again. This time, what I think he did different, was did not torqu as much down on the plug as before. Polaris told him that the ring on the plug was not making a seal. The compression from the engin was blowing the boot off. I tested it at the dealer before I left, and at this moment in time (lol), it appears to be fine. Hopefully this will fix my problem. I guess when I replaced the plugs the other six times, I did the same thing as the tech, but I thought he was aware of how tight is too tight. I don't feel so bad! [img]i/expressions/face-icon-small-smile.gif[/img]

Thanks again...

 

have you installed underdrive pulleys on your lightning? this makes one big difference.

 

Wow just when you think youve sean it all.Man thats a new one on me but it dose make sence...