The wife and I went out for a ride the other night. I got about five miles or so away from the house and my Trail started running on one cylinder. We were all by ourselves, so I decided to limp it on home that way. It was slow but steady. As we approached our driveway we could smell melting plastic. When I shut if off and got out we found the exhaust looking like this:

My theory is the raw fuel from the cylinder that wasn't firing built up in the exhaust and started burning from the heat of the catalytic converter. I didn't want to do it, but I sprayed the exhaust with the garden hose to cool it off and stop the body from melting. The plastic was already oozing away when we stopped.
It turned out that they never screwed the spark plug wires down into the coils when they built it, and one of the wires fell out as we were riding. I'm kind of surprised that it hadn't happened before this. Fortunately it didn't do any other damage.
I thought I'd pass this along so that my fellow Trail owners can take a look at their plug wires and make sure they are firmly attached to the coils. In my case the wires were just slid into the fitting on the coil, and the rubber boot was all that was holding the wires in. For those unfamiliar, there is a sheet metal screw type thing in the bottom of the plug wire fitting on the coils, and the wire has to be threaded down onto that to hold it in place.
The next time you have the access cover off your machine you might want to give your plug wires a tug to make sure they are firmly attached to the coils.

My theory is the raw fuel from the cylinder that wasn't firing built up in the exhaust and started burning from the heat of the catalytic converter. I didn't want to do it, but I sprayed the exhaust with the garden hose to cool it off and stop the body from melting. The plastic was already oozing away when we stopped.
It turned out that they never screwed the spark plug wires down into the coils when they built it, and one of the wires fell out as we were riding. I'm kind of surprised that it hadn't happened before this. Fortunately it didn't do any other damage.
I thought I'd pass this along so that my fellow Trail owners can take a look at their plug wires and make sure they are firmly attached to the coils. In my case the wires were just slid into the fitting on the coil, and the rubber boot was all that was holding the wires in. For those unfamiliar, there is a sheet metal screw type thing in the bottom of the plug wire fitting on the coils, and the wire has to be threaded down onto that to hold it in place.
The next time you have the access cover off your machine you might want to give your plug wires a tug to make sure they are firmly attached to the coils.