Just purchased this bad boy.cost rs.420/-. Gonna clean bike with it now.will let it dry off and wax it tomorrow.will post pictures.



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Ready for autopsy ...



This spring came out on first cut ..



Rust ..



The sequence ...



Rust ...



And this bugger is reading more than 200 kΩ now ...




So , now that I am clear what was my faulty part , and how they build the OE plug-cap - next project is to find a good quality replacement non-resistor plug-cap or rebuild this one without the resistance . I think I can replace the resistor and spring with a solid conductor piece in there , and fix the whole thing back together with epoxy , nahi ?

and this is a diagram of an ngk resistored plug ... ngk says that they use a "monolithic ceramic resistor" of 5kΩ

@ Shoeb - my champion is also bought from outside shop in federal-mogul packing . It runs fine though and I stow it as spare in the bike's toolkit now . Tested for around 1000kms of use .

The red plug-cap comes with recent bikes (including the new HF dawn) .. and I believe is for DC type ignitions . My Splendor+ has the old AC ignition . But the ASC did try to sell me that for my bike when I went asking to them for replacement cap , later they got me the correct one . I have no idea about it's resistance value etc . I would love to learn this too . For all we know , it may be of non-resistor type too . Best would be if you could measure that yourself , you just need a cheap multimeter and few minutes .

I have listened to you very much then and there engineer saab - just wasn't finding time to check it out earlier . When I did , I first checked the plug cap as you had said . And yeah , that saved me checking the whole electricals .
Ok , I am sticking to the OE cap for now , until I can get a non-resistor cap of similar quality .
Lovely roads & scenery , I envy you for the opportunity to ride such roads .... now how did you bag a banker's job ??!!

First of all I am sorry if I my post had been offensive or given a wrong impression that you had tried to prove me wrong.....in fact I look forward to be proven wrong so that I can learn much more....
I was only trying to put forward my thoughts in order to inform members on the points I observe while replacing stock Plug with an alternative....and share my personal bad experience with Champion with various engines, just like some from overseas ...
.I not only have my own experience ,but also look to see if it is one of a kind or, others in different environment,and driving conditions have any similarity with what I experience...
My guess on your problem with NGK in Joy vehicle is most probably due to wrong plug electrode gap...
Wish you all good luck always...

Sorry for the late reply I just recalled something- Around five months ago when I had overhauled my friend's passion,un-knowingly without inspecting the old plug and cap carefully I just replaced it with OE cap and plug as the cap was fitting loose.(You can say my lack of experience)

Today after going through this discussion AGAIN I started searching for that parts(I keep all the old parts in my store room) and found that it was running on a non-resistor plug and cap. Plug cap was made by SWISS and Plug was Mico U4A(both non resistor) and was surprised to see the uneven wear on the ground electrode which is not there in any of my collection of old resistor plugs (Mostly champions or MICO U4RA). Exactly as what you guys mentioned.

I am not able to find my camera,as soon as I find it I will post the picture.

The plug which I was talking about in my last post.(cleaned using a wire brush before taking this photo)




My champion PRZ7HC plug used for last 350 kms (before switching to a new non-resistor plug to test the difference).

I found out that if you are going to place a resistor inline to the ignition circuit (for mandatory radio supression or whatever reasons ..) , electrically the best place for that is nearest to the spark . So the resistor inside the plug is kinda ideally placed . Moreover inside the plug it is well protected from moisture and shock etc hazards . So I'd rather let the 5kΩ inside the plug be and use a non-resistor plug-cap instead .
Can you please measure the real resistance value of the SWISS made plug cap and post ? They are quality manufacturers and if it's non-resistor it may fit my bill . Unfortunately NGK is not marketing it's fine line of resistor & non-resistor plug caps in India .
Also carefully cleaned up my plug(cr7hgp) today , despite ngk's advice against cleaning the g-powers . It is now gapped at 0.75mm (recomended gap for the Splendor being 0.6-0.7mm) . This is because I've misplaced my wire-type gapping tool and that's the nearest thickness of feeler gauge blade I have . Hope it's gonna fire up and be ok tomorrow . It's a fast drizzle day here now on Sunday and just got up from a bad cold , so no ride test now .

There is no resistor in swiss plug caps-CONFIRMED. Real resistance value is 2 ohms which is actually the resistance of my crappy meter leads.
My splendor seems to settles down to a fine idle almost immediately now. Idling RPM is also significantly more with the same kind of tuning which was there with my champion plug.
I am cursing myself for failing in making a Digital tacho,it is now on my top DIY list to figure it out. But due to some ongoing issues with the turbo boost in my car,I am occupied with that in my free time. Need to install a boost guage on it to pin-point whether its the turbo or fuel related issue/boost sensor issue.
Any diesel junkies here ? I am suspecting a clogged boost sensor line.

Resistors in plugs are for controlling erosion on the ground electrode and nothing else. But the side-effect is that bike will fire less and thus will not feel free to rev.
Presently i am using MICO U4A on my joy and i am loving it. Idling will increase as the current is more and thus the bike is making more power.I do not know about other bikes but my joy came with MICO from factory and the plug ran for 30k.With experience you can tell whether the plug is correctly firing or not just by starting the engine. i learn this from my mechanic as he is so much expert that he just will listen to the sound and will tell if the current is thin or long, plug is sorted or not, bike is running lean or rich or tuning is correct.
He will tune the carb by feel and will tell you if plug will be red or white. And after few km when you open the plug you will see he would have told correct. Slowly and steadily i have learnt a lot from him.

regarding your car what is the problem it is showing. Give a little more description. I can try to help you as i have read a lot on diesel engines during my specialization on automobiles.

Great ! You are very lucky ! Now teach me also how to do that. Did you check the photo of the plug I posted ?

Just figured it out - As I suspected it was the turbo boost sensor line from intake manifold to Fuel Injector pump which was clogged up . Removing it was a Pain in the @#$ as heater, coolant lines,air box,pcv needs to be removed.
As a result extra fuel was not being injected even though extra air was being pumped by the turbo.
Symptom- No sudden feeling of acceleration,pickup decreases when accelerator is pushed, No black smoke even under full load,sluggish performance at ghat sections.
I have also removed the intake manifold to clean it up. Working on diesels is a messy job.

Do you know Lucas Diesel injector pumps used in Indica/indigo ? Do you have any information on that ? Did you get the parts catalog from your friend ?

If u think resistor is well protected inside the plug then i think u should read this useful link Spark plugs. Why you should check yours, today! | Platinum Aviation Blog (originally posted by psr ji)
If the value of resistor inside the plug increases over time then its a bad plug. This thing happens with champion plug therefore it shows such abnormal values.
Also we know resistor dissipate current as heat so i think resistor plug will be more hotter than non-resistors. IMO, which is not good for highway driving. They can be more hot in summer.

We have resistor caps installed form so many years which have already suffered every worst climate, and still they are under recommended range i.e, 4~5k ohms.
So my thinking is,... why to have non-resistor cap if they are always perfect in every condition

I'm too loving it bhai after using U4A, my acceleration & pulling power has increased. and bike is running now on less throttle opening. I would say, great noticeable difference

I am seeing so many posts on the subject of to " resist "or not.......I honestly hope a small observation by me doesn't cause much hardship to members here..

But I am loving every bit of it. Please keep posting your observation and experiences. We never know when it may come handy.

Ok then here is some more for and against Champion plugs....

Are Champion Spark Plugs Garbage? - SmokStak

Changing the spark plugs & brands to avoid - Ninja250Wiki

Spark Plugs

@psr- What do you mean by hardship? Nothing is hardship but it is a chance to learn everything about technology or new things. My this quest for automobiles has brought me to where i am now. So learn what you have interest because learning never stops and once you stop learning then it is as good as being dead.

@all-
RESISTOR AND NON RESISTOR
There has been a lot of debates on both the plugs and even i had advised paul to go for non resistor plugs over phone. Yes, he regularly calls me.
If your bike has gone old then go for non resistor plug as resistor will always show hindrance in flow of current.So nothing to worry. Even i got the news from my retailer friend that NGK is also coming out with non-resistor plugs across all models as resistor model plugs are facing lot of problems. Most probably in 2-3 months time ngk will come out with non resistor plugs and will be better than present line of resistor plugs. For your knowledge most high performance plugs do not have resistor and thus provides better performance then normal plugs.
I am loving this discussion as i have experienced a lot on my joy and also have gained a lot of knowledge. So i like it when i am helping my friends here.

@shoeb- do not worry i will make you learn how to know bike state just by hearing the sound. Let me be regular here and then i will post here.
Regarding those LUCAS fuel pumps ask me what information you want and i will help. Generally talking about complete pump and its working and all that it will take more than ten pages here if i go to minutest details about the pump. So please be specific about what information you want.
May be we should create another blog where only technical discussion will take place and not only about bikes but about complete automobiles as a whole.
There is no need to go for non resistor plug caps as it will cause radio interference and is not recommended. And also non resistor plug doesn't comes in good quality. While swiss is a good company but still it is not as good as OE cap. Believe me as i have also used swiss plug caps during a short time.
Your discussion about plug cap has reminded me about my joys plug cap as i have not checked it in these five years. Five years means approx 1 lac km. I will most probably check it next saturday when i return to bhubaneswar.

Another thing i like to add is that previously as i was using the joy everyday i couldn't know the difference, but now since i am using it after a gap of four days so now i am knowing the difference.
Man this bike feels like almost a new bike. The smoothness is unmatched. Compared to my joy, my extreme feels vibrating, gears feel hard, sound seems mellow. But the joy after 12 years still feels better than my new extreme. Of course when it comes to performance, it is no match for my extreme, but still it is up there and feels like running for ever without any problem.
If somebody tells if there is zero maintenance bike then it will be my joy. Nothing seems to wear out. The present chain sprocket is running at 93,000 km and still doesn't shows any wear even though it is so old.
Although i do not ride it now often as before but i love it more. May be somebody said correct distance increases love.

@all- I am completely pissed with you all as i am thinking of writing my extreme ownership and buying review but this technical discussion is pulling me towards here and i cannot write the review.

Thanks for the kind words of encouragement....here is a link to a very exhaustive write up on Auto mobile Ignition ...

Breakerless Ignition

and a write up about the different type of Ignition wire cores and their effect....

Truth About Ignition Wire Conductors