[Whaler Bob]

Hello, I'm looking for advice on changing the spark plug wires on '68 40HP Evinrude. I've got the service manual, and it describes changing the coils, but not the wires. I have removed the flywheel. What's not clear (to me) is how the wires attach to the coils and whether I need to remove the armature plate or not. The wires are routed underneath this plate, the manual says to remove it when changing coils. I just want to replace the wires. Any words of wisdom.
I have searched the messages here and saw some good advice on what type of wires to use when I do change them.
Thanks,
Whaler Bob

[lindy46]

You can change the wires without removing the plate, but it's a lot easier if you take the plate off. You have to remove the coils to get to the wire connectors anyway, and two of the coil bolts hold the plate in place. there are only two more bolts which hold the plate down. Once the plate is removed, it's easy to work on the wires from underneath, and there are several wire hold down bolts which can be easily removed. Pull the old wires off and install the new wires through the proper places in the plate, leaving a little slack at the coil end. Then screw the new wire ends into the coils, and pull on the wires slightly (to take up the slack) while fitting the coils back into place. Once the coils/wires are installed, replace the hold down brackets and put the plate back on. I usually leave the wires long and cut them to the proper length once everything is back in place.

[kbait]

Yep, Pull the plate. It's really easy once you do it. I work on these all the time, and I learned long ago that whenever I service one, I pull the plate, replace the plug wires (using the old caps and connectors), inspect the coils for cracks, remove points and file ALL pit's out, then reassemble, gap the points, properly torque flywheel, and check spark with my tester. They always test fine after that, and I've never removed the flywheel again because I missed something. Good luck!

[Whaler Bob]

Thanks for the good advice. I'll read up on disassembly and give it a try. Can you tell me how the wires are attached to the coils? Are they screwed in, or does the little cap just pull out of the coil along with the wire?
Thanks again,
WB

[tx1961whaler]

The spark plug wires just push into the coils. Make sure to use the wires with actual stranded wire in them, not the carbon type auto wires.