FZS600 2000 ignition cables

[alchemyx]

Hello,


For about two years I had issues with ignition of my FZS 600 ('2000). Usually after rain it had trouble with working unevenly (defnitely not all plugs were giving proper sparks). So I replaced all spark plugs and it helped for a little while. Now it started again and it happens only after rain or washing. Last time after rain it would even start (starter was working fine but firing) I had to give it some acceleration before it would start.


So I think that time has come to replace cables or seal them with ignition sealer. What do you think? If I had to replace them do I need to do that with coils? They are glued together with cables.


Any help would be appreciated. Thanks!

[andybesy]

Hi alchemyx,

Short answer: I'd change the spark plug caps.

The HT leads are formed as part of the coils and so must be replaced together if that is really necessary. Commonly found on ebay for not a lot of money.

But most people find it's sufficient to just replace just the spark plug caps, and trim 0.5cm or so off the end of the existing HT leads to ensure a good connection (ensuring they'll still be long enough).

If you're familiar with the use of a multi-metre to measure resistance then you can test your existing coils (both sides), leads and caps to see if they're within spec.

It's quite simple to de-assemble and re-assemble, and you can find the resistance specifications in your haynes manual.

You'll probably find your caps have gone out of spec and should be replaced. They may even be arcing to the head when wet.

As far as water is concerned, new caps may help, but also a good spray with WD40 can't hurt either.

Hope this helps, and let us know how you get on.

Andy

[BBROWN1664]

Have you got the piss flaps in the right place? They should be resting on the front rocker cover to shield the plugs from rain and spray and allow water to drain off towards the front of the engine rather than into the plug wells.

[Fazer99]

Are the clocks going crazy and are you getting a lot of popping and back firing from the exhaust?

[alchemyx]

Hello,


First of all thank you for all replies. I will reply to all of you in one post to keep it clean:


 @Fazer99 - clocks are fine, and there is no popping or backfiring from exhaust.
 @BBROWN1664 - flaps are in right place but usually sides of bike are getting wet from the roadso are cables and plugs
 @andybesy - I can handle multimeter and will do measurements in few days but question is how to do it properly? I have a servicing manual that says that there should be JO313 Denso Coils with 1,87 0 2,53 Ohm on primary and 12 - 18kOhm on secondary winding. Should I do measurements with cables (especially secondary where cables are unremovable). Also it says that there should be 10kOhm resistance on spark plug cap. Where should it be measured?


Thanks!

[Fazer99]

I asked about the clocks and exhaust as I had similar problem with my bike recently and faults with the clocks and exhaust where the added problems which turned out to be faulty wiring from the regulator/rectifier to the starter solenoid.

[Fazerider]

When measuring the secondary, take the plug cap off and touch the probe direct to the copper core of the HT cable. The cap can be checked separately.
However, a multimeter is only of limited use for checking coils. An open circuit will show up OK as will a serious short, but quite often a coil will develop a short between two adjacent turns. The change in resistance is miniscule leaving the total well within specification, but it'll kill the spark.
A more reliable way of checking the spark is to take an old plug with the gap opened a few millimetres, stick it into the cap and thumb the starter while holding the plug against an engine fin. Provided you're not in bright sunlight you should see a healthy spark.

[andybesy]

Fazerider, I've often wondered about the spark plug checking method you described.

I used to do that back when I was a kid with single cylinder two stokes, but haven't ever done that on a 4 cylinder.

Can you do it safely without it either a) starting to run on the remaining 3 cylinders or b) spitting fuel out everywhere?

Just trying to get it straight in my own head.

Thanks, Andy.

[Fazerider]

Yes, it'll probably run on three, that's why I use a spare plug and leave the one in the head alone. You may get the odd pop from the exhaust from the unburnt fuel but at least it doesn't try to set fire to your face. 

[Carter]

It'll just sound a bit noisy running on three with a plug out, there's not much going on in the cylinder as there's no vacuum to draw air and fuel in with the plug out. I think yamaha say the spark should jump a minimum of 6mm when the ignition system is healthy. I've had problems with my plug caps, a few forum members have told me the NGK caps work perfectly well. The originals are bloody expensive.

[alchemyx]

Hello,


Did my measurements and:


coil 1-4, primary 2,5Ohm, secondary 15,76Ohm
coil 2-3, primary 2,6Ohm, secondary 15,69Ohm


Now to the caps:


1 - 9,6kOhm
2 - 9,6kOhm
3 - 10,75kOhm
4 - 89kOhm


So coil seems fine, but caps are weird (specs says 10kOhm). It still wont start, but if I give it some throttle it will but it will work unevenly (like 3 cylinder) and after some time there will be gasoline driping from near carburetors (is it normal?)


What are you recommendations - replace caps? If yes - what are NGK model numbers?

[Fazerider]

If you have fuel dripping from a carb it's not normal, it's flooding. Various things can cause this:
dirt jamming the float valve open, the valve tip or the O-ring that seals the valve to the body of the carb being damaged or a leaking float.
The NGK plug caps you need are model SD05F, about £2 each.

[alchemyx]

I am way too unskilled to check that, so I will probably ask someone to do my carbs.
About caps - do you think they need replacing? Also strange thing is that SD05F 5kOhm not 10kOhm

[His Dudeness]

Trim the ends off the ht leads and replace the cap with ngk. That usually solves this issue. Don't worry about carbs until you confirm you have good spark

[alchemyx]

Hello! I will order caps in few days but it seems there is trouble with fuel system or carbs because i checked and I have a spark on every cable


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[alchemyx]

Hey! Replaced caps, also replaced carbs orings and overflow valves and works as new. Thanks everyone!


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