plug wire melting

[shocko]

well heres one for the gurus... 1975 gl 1000 plug wire #2 overheating and melting??????????
coils changed
plugs changed
carbs cleaned and set
valve clearence checked

ANY IDEAS................ HELP

[dingdong]

Was the wire melting before the repairs? Possible loose plug wire where it screws onto the cap causing spark arcing. Possible loose connector between the spark plug cap and plug. Check the resistor inside the cap. Possibly that cylinder is burning extremely lean (carb problem) causing it to overheat. Pull the plugs and compare #2 to the others.

[Placerville]

Those suggestions are good. If it were mine, I'd have replaced the plug wires and caps along with the coils and plugs to do the job 100%. I suspect you have a plug wire that's arching or, if you have them, a resistor cap that's gone bad. Install new wires and caps and your problem will probably be gone. Also, those new wires and caps will provide for a better spark.

[Fred Camper]

What were the coils changed to? You cannot fine NOS, so did you replace with 35 year old coils or new aftermarket? New coils are important for any ride in the rain. Placerville rocks with great info.

[shocko]

ok thanks to you all BUT problem not solved,
new plug wires
coils off another good running bike
plug caps changed

GOING CRAZY HELP!!!!!!!!!

[Placerville]

OK, let's review this to get grounded:

Your #2 plug wire (left/front as you're sitting on the bike) is overheating and melting. Correct? Since observing this, you have:

- Replaced both coils with another known working pair of the correct type.
- Replaced your plug wires (or at least the #2 plug wire).
- Replaced your plug caps (or at least the #2 plug cap).
- Replaced your plugs (or at least the #2 plug).

Correct? If that's the case, my only other suggestion is your ignition. The 1980 has Honda's 'first year' electronic ignition and, as far as I can determine, it's the only remaining cause of your problem.

[Fred Camper]

Now Placerville, if I read the above correctly this is a 1975 GL. So stock is points and capacitor. Now it may have been updated to electronic ignition but if so we do not know the age. On my 1977, last year I replaced my Dyna III which was clearly dated like 1982. So this 1975 may have points, an old electronic ignition or a new one.

So Shocko, can you answer that one for us?

[Placerville]

Whoops. I was looking at his info. on the right side of his post (1980) and got off track. Well, I'll stick with the 'ignition theory' for now as I'm at a loss as to what else it could be.

[shocko]

thanks again, 1975 gl converted to electronic ignition witch has been widden for 1000s of kilometers witch this ignition
???????????????????

[dingdong]

Lets not forget that the each coil fires 2 cylinders. Have you pulled the plugs to see what #2 looks like compared to the others?

[shocko]

checked against other3 mixture is not lean , all have nice bisctuit colour.???
not giving up!!!!!!!!!!!!!!!!!!!
plug itself out side is silver with no sighs of overheating

[dingdong]

In re-reading this I don't see where have you changed the plug caps. Just the wires???