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Old January 4th, 2023, 05:40 PM   #1
Shafer
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Broken spark plug cap clip springs

One of my 250s have broken spring clips in the tips of the spark plug caps. Both caps what are the odds.

There is no resistance when pushing a spark plug on, so I'm worried it will cause problems.

I've tried a few failed attempts to make my own spring clips on the brass tip end but nothing trustworthy.

Any ideas on a budget fix or a aftermarket replacement that would work?
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Old January 5th, 2023, 11:54 AM   #2
ducatiman
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MOTM - Nov '18, Mar '17
Budget? fully disassemble the spark plug cap..... remove/fit (cutting to length as necessary) a clip from the back of a pin-on type badge

The next step? COPs ....do a coil over pug mod

link:
https://www.ninjette.org/forums/show...highlight=cops
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Last futzed with by ducatiman; January 5th, 2023 at 04:48 PM.
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Old January 6th, 2023, 10:13 AM   #3
Shafer
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You are a genius! A safety pin was the perfect material to use. I'll look into the coil overs some more.

Thanks for your help!
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Old January 6th, 2023, 10:16 AM   #4
Shafer
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Here's what I did to repair this.

Step 1: get a safety pin

Step 2: cut sharp end off

Step 3: bend a little hoop at the end

Step 4: insert your hoop into the notched side, confirm you can see it from the top.

Step 5: hand wrap the pin round the groove in the top

Last futzed with by Shafer; January 6th, 2023 at 10:27 AM. Reason: Adding more details
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Old January 6th, 2023, 10:20 AM   #5
Shafer
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Step 6: cut off pin end

Step 7: pull the wire around the notch at the top tightly while holding your finger over the hoop peice to keep it in place.

Step 8: cut about where the X is in the picture you need room for all the pin to be pushed into the groove

Step 9: use needle nose pliers and go round the top of the groove pushing the pin wire in

Step 10: test out your work. If your hoop in the hole is blocking the hole for your spark plug hold the pin in the groove and use a small screw driver to bend the hoop over to the side.

988D5B2A-63CF-4D37-8F53-F6AFFDEB71E0.jpg

2F2327CF-31EA-46C0-AA3F-F3E553230190.jpg

32171BF7-305E-473E-92FE-36A387508CF6.jpg

2D0AA9B4-42E1-4E10-B593-37E7D0554C05.jpg
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Old January 6th, 2023, 11:31 AM   #6
ducatiman
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good choice on safety pin
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