300/440/550 CDI igniter question

On the fly NY

On the fly NY

Location
nj
Thought I would swap out the old spark plug wires on the 550 I am in the middle of restoring/rebuilding (first time doing a ski). I am stumped on the way to do this now that I see the CDI igniter is a sealed unit without access to the end of the wires. Anyone here have experience with this and willing to share the secret? I would greatly appreciate any and all help. I know it is possible, I have seen pics of rebuilds with new wires for the plugs. Thanks!
 
WFO Speedracer

WFO Speedracer

A lifetime ban is like a lifetime warranty !
Location
Alabama
The secret is you have to make a special cutter out of appropriate sized tubing, cut teeth into the end of the tubing then use it carefully in a drill to remove what is left of the old spark plug wire, the spike that the wire pushes into is buried quite deep into the coil and you have to be careful not to damage it .

Or you can do it like the guy in the video does it , but to me his way looks kinda cavemanish.

.
 
On the fly NY

On the fly NY

Location
nj
well, scratch that idea then...they still work fine, just thought I would put fresh ones in ...thanks for the video, enlightening!...next question, is about finding an exhaust tube....I have a '87 JS 550, exhaust on the right....I have seen exterior exhaust tubes running down towards the water line and would like to get one but haven't been able to find one...what are they made of, can I fabricate myself?...thanks
 
WFO Speedracer

WFO Speedracer

A lifetime ban is like a lifetime warranty !
Location
Alabama
The exterior tubes are the older 400's 440's and early 550's , 86 -89 had right side exhaust then everything went to rear exhaust starting in 1990 .

There should be plenty of those tubes, exhaust exits and holders floating around , I probably have some here somewhere on an old hull , but that really isn't any kind of an upgrade , rear exhaust would be an upgrade..
 
On the fly NY

On the fly NY

Location
nj
for this project I wont be routing the exhaust thru the stern but would like to do a similar set up as in the pic below, although on the right side...do you have any of these parts?...the current exhaust port is the 3 rivet pattern...thanks
 

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WFO Speedracer

WFO Speedracer

A lifetime ban is like a lifetime warranty !
Location
Alabama
I am sure I have an stock outlet , I will have to check on the hose and the hose holder , if memory serves me I believe that hose holder is side specific, I am not sure if it will work correctly if you flip it over and try to use it on the right side.
 
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