My write-up on servicing the spark plug caps,
Even bad plugs should do something, unless they are totally shot.
Did you renew the HT leads, and disassemble the caps?
Make sure you disassemble the caps, and clean them, and yes the caps get cruddy.
Here my write-up,
Quote:
Short explanation: The inside of the hard plastic caps accumulate crud the can short out the spark. This can cause rough running or failure to start. Every time you do any work on the bike: remove them disassemble and clean them and renew the wires or at least the connections.
The long Explanation, Warning engineering information can cause Drowsiness.
The ancient cylinder design of the engine dictates that the spark emanate form the center of the combustion chamber. In order to get it there, the plugs had to be located down deep in a well between the cams. This well is a perfect place for dirt and moisture to accumulate. Then because there is no cooling water at this point the metal around the plug runs very hot. Surround this with the large amount of cool metal and you have a recipe for condensation. Now K did drill a drain hole between the fins to help (a little) but it often gets plugged up.
The moisture boils off the base of the plug and the vapor condenses on the cool plastic cap and the plug insulator. This moisture forms a easier path for the electrons to ground than jumping the gap at the plug to make a spark. Misfire.
This issue is right up there with Pilot jets as a cause of trouble.
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Here's some pictures that might be helpful. I took these when I replaced the wires themselves, as it was a good time for a write-up, and the wires were OEM from 1998.
Wires are just 7mm copper core, with clear silicone jacket
IMPORTANT NOTICE: make sure to use a proper screwdriver, make sure it fits, as the parts are made of brass inside the spark plug caps
Important notice: the wire must be screwed on the spark plug cap, note the screw like object inside the spark plug cap?
Important notice: be careful to not loose the ferrules on the HT leads, these keep the wire from falling out of the coil. Below is an example of ferrules on a pressure fitting, looks familiar?
Also keep in mind doing the CoPs conversation/modification, it helps eliminate the spark plug caps, HT wires, and it provides a better/stronger spark, which does allow you to open up the plug gap.
Kawasaki ZX Ignition Coil Pack/ coil over plugs (CoPs) modification.