Stick coil mod

[Superfour Tom]

For anyone wanting to get rid of crusty old HT leads or Knackered coils, This is for you 

Did this mod today. Nothing in particular wrong with my coils, the HT's were just stiff, Cracked and oxidised at the end.
Simple enough, Coils used are 636r ninja (unsure on the year).

Standard coils read 2.5ohm's (YMMV)
636 read 1.3ohm's (Will obviously double up to 2.6ohm's in a pair)

Very simple Simple loom, Just 2 pairs wired up in series, Drew up a little diagram.



Installed:




Hope this helps.

All the best,
Tom

[limax2]

Welcome to the site Tom. Always good to see what others are doing. Interesting mod that and not seen it on a Fazer before.

[alexanderfitu]

Are the spark plugs connected straight to the coils then? no HT leads?

[ade the blade]

if i`m not mistaken, wires leading over to `cap` are the primary circuits ( l.t ) as the coil / h.t circuit / spark plug cap are all combined into one nifty unit. neat little mod that.well done !

[alexanderfitu]

Thats what I thought, will keep that one in mind when my leads wear out!

[Superfour Tom]

Exactly, Coils are contained inside the 'Sticks' which are also the spark plug holder. No more crusty H.T leads. 

[mars696]

Let me ask something.
The oem coils,feed plugs 1 and 3 and the second feed plugs 2 and 4.
On the diagram you have draw the pairs are 1 and 4 ,2 and 3.
Isn't this wrong?


Overall nice mod.
Any difference spotted?

[ade the blade]

Let me ask something.
The oem coils,feed plugs 1 and 3 and the second feed plugs 2 and 4.
On the diagram you have draw the pairs are 1 and 4 ,2 and 3.
Isn't this wrong?


Overall nice mod.
Any difference spotted?

no mate..Tom`s drawing is totally correct. coil nearest frame is for 1 and 4. cheers Ade

[red98]

good mod that    thanks for sharing tom......ht leads dont last forever,a good solution thats looks factory fitted  :thumbup

[Chris]

Thanks for the post, great idea 

Chris

[Kamikaze]

i know this is an old thread, but its the only one i found.
im having some misfiring issues and cylinder 3 is the culprit. ive replaced the plugs and have ngk caps fitted. trimmed the ht leads to freshen them up, and still not running right.
i was looking t replacing the coils and thought about upgrading.
has anyone else, tried this mod and how did you get on?

stupid question, but, want to make sure im reading it right, but, the +- wires at the bottom of the diagram are going into the loom right?
a in, they would be the terminals on the oem coils as standard. or is there a modual seperate to the individual coil packs on the zx636?

[Disorderlypunk]

im now looking for the plugs (loom side) so i can do this mod and make it look factory
have a feeling one of my coils is on its way out so i feel i should try this
(also need the space by getting rid of the oem coils so i can hide the other shit i dont want to see)

[Bretty]

If your problem is with cylinder 3, the first thing I would do is swap the leads over between cylinder 2 & 3. They are both supposed to spark at the same time. If your problem then moves to cylinder 2, you know the problem is with the leads. If the problem stays with cylinder 3, the issue is that cylinder (carbs , fuel, air issue)

[Kamikaze]

Hoping to get a chance to try this in the morning before work


I'm hoping to solve this issue before splashing out on a brand new stainless exhaust system. Don't want to do that to find something drastically wrong with the bike after splashing out.

[Disorderlypunk]

seems strange to go for an exhaust to fix a firing problem lol

[Fazerider]

i know this is an old thread, but its the only one i found.
im having some misfiring issues and cylinder 3 is the culprit. ive replaced the plugs and have ngk caps fitted. trimmed the ht leads to freshen them up, and still not running right.
i was looking t replacing the coils and thought about upgrading.
has anyone else, tried this mod and how did you get on?

stupid question, but, want to make sure im reading it right, but, the +- wires at the bottom of the diagram are going into the loom right?
a in, they would be the terminals on the oem coils as standard. or is there a modual seperate to the individual coil packs on the zx636?

This really isn’t the way to convert to stick coils. It guarantees a weaker spark at high revs because the coils are expecting 12V pulses across the primary. Putting them in series gets the total resistance to match what the old coils presented to the ignition box, but halves the voltage.
Ideally you would use a buffer circuit to drive the coils properly and protect the ignitor box. (Though that may not be necessary, it depends what output devices the box uses.)


Either way, modding the system isn’t a good solution for your issue. If cylinder 2 is OK you can be sure the coil isn’t the problem. It could be the lead or plug cap or plug shorting the spark to ground, but the coil is OK.
What colour is the business end of the plug? I’d be much more suspicious of the mixture before looking at the electrics.

[Kamikaze]

seems strange to go for an exhaust to fix a firing problem lol

Think you misread my comment.
I want to fix the firing problem before I order my exhaust.
Seperate altogether but pointing out I'm wary of spending big on the full exhaust system only to have to spend big on the engine if I can't fix it. One thing at a time.

a quick look at the bike before work i managed to fire the bike up and pull each plug cap off and only number 3 came off without the bike idle being effected. so 2 and 3 on the same coil but only 3 was effected.
then swapped cap 3 onto spark plug two and fired it up, again, pulling it off dropped the idle. couldnt get to try lead 2 on spark plug 3 as it wouldnt reach (dont have time to take things apart before work to make it reah) but im guessing it wouldnt have done a thing.

so as you say, coil appears to be okay. and im guessing by the fact i put the lead and cap from 3 which wasnt running onto two which was, that rules out the caps or leads being at fault either.

next step clean the carbs? strip them off the bike or carb cleaner into the intake while its running?
i did drain the 4 bowls the other day and there was plenty of small bits of debris in each bowl. but didnt remove the bowls or the carbs at all.

[Disorderlypunk]

before removing the carbs as it is a ball ache with the airbox are you able to do a compression check
it can give you ideas of what could be happening that can save a lot of time removing carbs refitting then figuring out its
something different like a blown gasket or non seating valve and having to remove all over again
i made this mistake once and wasted an entire day