The tester had a chamber that was connected to compressed air and had a window that allowed you to see the spark that was generated by the machine. It didn't take as much pressure as you would think to "Blow Out" the spark on a weak plug. I don't remember the exact PSI for this to happen, but I think that just over 100 PSI would cause a bad plug to fail.
A new, properly gapped plug would never fail. even at 150 PSI, which was as high as the compressor would go.
I think that your theory about the wires and caps is correct. Small micro-fractures in either could cause spark failure when the engine is running and not be so apparent when outside the engine at atmospheric pressure.
The wires on the Suzuki coils are metallic. My guess is that a Cap or the connection to the Cap is the problem.
I am running Accel coils with 8.8mm Stainless Steel core wires and no resistor Caps. I got tired of chasing ignition problems.
Get that beast running!
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