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How To Repair A Spark Plug Boot On Chainsaws

by JEREMY HIPA 29 Aug 2022 0 Comments

Sometimes the boot is extremely hard to get off the plug, the small metal clip would break and be stuck on the spark plug when you try to replace the spark plug, like this:

It is the small metal part on the spark plug that is usually inside your spark plug cap.


Before the replacement, you need a new connector, a plier and a pair of cut-resistant gloves.
Step 1: You need to just remove the plug and not bother taking the metal part off the top of it.
Step 2: Check the inside of the boot if there is the other part of the metal clip. You can pull the boot off the wire, and you can see the other part if there is.
By the way, the procedure will apply to all gas chainsaws.
Step 3: Grab your new connector to put it on the wire. Because the end of this little piece is quite sharp sometimes and now you need to squeeze it into the wire with pliers. It is important to squeeze it in the middle of the wire so that it touches the actual wire inside.
The next step is where a lot of people have a problem.
Step 4: You need to get the spark plug boot over the connector. Here is a quick trick here that makes it easier. You can spray some lube on the back of the spark plug boot to make it easier to slide it over the connector. Now you need to hold the connector at the wire and get the boot on because it really has to stretch. And you can also spray some lube on the connector.
Step 5: You should keep holding the metal part as long as you can to prevent it from coming out.
If you are not using a small metal part inside, it might be a bit harder to push it in because it might be shaped differently. But if you hold the wire again with the pliers here, it makes it easier to push it in.
Step 6: Now you need to flip the cap over and make sure you can see that metal part on the inside. If you see that it is not quite at the end, you can put a screwdriver in there, and just force it up a bit.

A small tip: If you want the spark plug boot to come off more easily from the plug next time, you can put a bit of dielectric grease.
And now you can test out your saw to make sure that everything has been put on right.

Please let us know if this works and if you have any suggestions or comments. Or you can join us to feature your passion for repair projects, share your stories with the Hipa family and also get help from Hipa.

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