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daws0n |
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daws0n Borekit Bruiser
Joined: 03 Jul 2017 Karma :
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Posted: 17:35 - 30 Nov 2019 Post subject: Kawasaki ER5 mis-firing how to change HT leads on the coils? |
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I'm trying to diagnose a mis-fire on the right hand cylinder on my ER5, it's been running rich for a while and has got to the point where the bike isn't working well at all.
I've changed the spark plugs (both filthy black) and plug caps, and checked the coil's ohm resistance readings on both sides... All checks out OK according to Haynes manual.
The HT leads don't look damaged but I'd like to replace anyway just to rule them out as a point of failure. I've picked up a couple of lengths, and the new cable screws onto the spark plug caps as expected. On the coil side getting a firm connection is not so obvious...
I've unscrewed the small plastic cap that secures it to the coil and original cable just dropped out. There is no bare wire exposed on the cable side, but I can just about see a small screw in the barrel (but it's not enough to grip). See photo 2 here to see what I mean
https://www.ebay.co.uk/itm/ER5-Ignition-Coils-Genuine-Kawasaki-2001-2006-640/193203842086
Any advice would be much appreciated!
Thanks |
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Nobby the Bastard |
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Nobby the Bastard Harley Gaydar
Joined: 16 Aug 2013 Karma :
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stinkwheel |
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stinkwheel Bovine Proctologist
Joined: 12 Jul 2004 Karma :
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Posted: 18:38 - 30 Nov 2019 Post subject: |
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From memory it screws on with an olive like a water pipe fitting. The little screw is a spike to go up the middle of the cable to make contact.
Have a look inside that screw-on cap, there should be a little rubber grommet type thing that you slide onto the cable between the the coil and the cap then screw the cap down on top of it. It's probably stuck to the inside of the cap or still on the old cable or the coil itself ____________________ “Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles. |
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daws0n |
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daws0n Borekit Bruiser
Joined: 03 Jul 2017 Karma :
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stinkwheel |
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stinkwheel Bovine Proctologist
Joined: 12 Jul 2004 Karma :
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Posted: 23:21 - 30 Nov 2019 Post subject: |
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I can't say I ever actually changed one so I don't know if it's moulded on or not, I have had them apart.
Check the coils are making a good earth connection with the frame and their bracket, corrosion under here is a known issue with all those 500 twins. ____________________ “Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles. |
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daws0n |
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daws0n Borekit Bruiser
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stinkwheel |
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stinkwheel Bovine Proctologist
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daws0n |
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daws0n Borekit Bruiser
Joined: 03 Jul 2017 Karma :
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Posted: 12:11 - 01 Dec 2019 Post subject: |
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Sound advice, nice one fella
I'm going to have another go at it now, then off to check out a CB500 this afternoon. It looks like a similar bike size wise and is a much newer machine (2016).
Being an all weather rider I've always gone for for cheaper older bikes, not so much heart ache when the road salt and winter riding gets to them... If I can get my er5 running well again I think I'll keep it as a winter hack. It's not a bad commuter when it works! |
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daws0n |
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daws0n Borekit Bruiser
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stinkwheel |
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stinkwheel Bovine Proctologist
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daws0n |
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daws0n Borekit Bruiser
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Posted: 22:22 - 01 Dec 2019 Post subject: |
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Problem remained on the right hand side. Bike started OK but as soon as I pulled off the drive way I could tell it wasn't going to run right, struggled with with an upward climb and as soon as I got on the main road fuel started to explode in the exhaust. When I opened the throttle wide the bike momentarily regained power, but only for a few seconds. When I got it back home I revved it a few times in neutral and a small puff of black smoke came out of the exhaust. The left hand cylinder was hot to touch but right hand was barely warm.
In other news, I am now the proud owner of a Honda CB500F Size wise it's similar to the er5, but the power delivery and handling are very different. It's done <4k dry miles and is in excellent condition, too nice really to used in the winter...
I'm determined to get the er5 back up but at least now the pressure is off for commuting duties. I'll try swapping the plug caps over next weekend... A local garage has also offered to lend me a CDI box from a broken er5, could be worth swapping that over as well? |
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Nobby the Bastard |
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Nobby the Bastard Harley Gaydar
Joined: 16 Aug 2013 Karma :
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daws0n |
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daws0n Borekit Bruiser
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stinkwheel |
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stinkwheel Bovine Proctologist
Joined: 12 Jul 2004 Karma :
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Posted: 14:23 - 02 Dec 2019 Post subject: |
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Might be time to do a compression test.
Could still be carbs. The poor running but picking up on wide-open throttle thing sounds suspicious. There are "power jets" in the carbs on those bikes. I've had them block before and they are a total sod to clear. They leave a big hole in the carburettion that doesn't clear until you're fully on the main jet (about 8,000rpm+).
You can see the power jets as little holes round the edge of the airbox side of the carburettor, facing backwards. They are fixed, and can't be removed for cleaning, just a case of lots of flushes through with solvent and compressed air.
I wonder, did they check the carb diaphragms when the carbs were serviced?
Might be worth checking the float height in case the needle valve is sticking. The ones on my old KLE did this (virtually the same engine). They got corrosion on the sides of them that was making them stick in the seat.
That's reasonably simple, just put a bit of clear hose on the float bowl drain, run it up alongside the carb and crack open the screw. Put the fuel tap on prime or turn the engine over a few times. The level of fuel in the pipe is the float height. It should be roughly level with the joint on the float bowl (workshop manual will have a prescise measurement). It could potentially be either way too low or way too high if the needle is stuck. ____________________ “Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles. |
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Old Thread Alert!
The last post was made 4 years, 118 days ago. Instead of replying here, would creating a new thread be more useful? |
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