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Old August 30th, 2015, 09:05 AM   #1
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Kawasaki ZX Ignition Coil Pack/ coil over plugs (CoPs) modification.

I've decided to do the coil over plug modification on SERENITY, so first step was to purchase the coils.

After looking on eBay I found a set for 00-02 Kawasaki ZX6R ZX6 05-08 ZZR600 Engine Motor Ignition Coil Packs w/ Harness, for a total cost of $30.00. Must have the harness which is needed to adapt the Ninjette wiring to the coils. It's important to get the harness, because the coil connectors are different.



Next step was to unwrap the coil harness, so I could cut the OEM connectors from the harness.



Cut at the OEM splice points, which there are two.




OEM connectors ready for modification.




Wiring is easy just connect the red to the red wires, and the other wires to each other.

SIDENOTE: temporarily I've put male blade ends on the coil over connectors, so to just plug them into the existing wiring on the Ninjette. I did this while I'm testing these out, if something goes wrong I can easily plug the old ones up. Once I'm confident in them I will splice and solder them permanently, and removing the OEM coils

After that it's just as simple as installing the coil overs like you would the regular plug caps.



Removed the OEM coils



Final verdict: no real noticeable difference between the OEM Vs ZX coils. The advantages are eliminating the plug wires, and the spark plug caps, which need to cleaned, less to go wrong hopefully. After testing, I decided to remove the OEM coils, and brackets, which by the way they were spot welded on.





TECHNICAL UPDATE:

It has been pointed out that one might want to increase the spark plug gap, to match the gap that these coil over plugs,

Quote:
07-08 Zx6 Spark Plug Gap: 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
To take advantage of the higher output of said coils, and better spark.

I will of course try this, and report back, but if you do this modification you can do the same, and report your findings.
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Old September 15th, 2015, 01:11 PM   #2
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Old October 30th, 2015, 04:05 PM   #3
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Update:

Some concerns about supporting the CoPs has come up, so I decided to look into this.

The fix is simple, remove the rubber tops from the OEM plug caps, and install them on the CoPs. You will need to remove the small rubber ring on the top of the CoPs, and slide the OEM rubber on, after that your all set.









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Old February 21st, 2016, 04:03 PM   #4
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CBR600RR CoP's fit perfectly, just tall enough to fit tthe wiring connector.
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Old February 21st, 2016, 04:28 PM   #5
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Thx u for the feedback, any other observations? Good or bad?

Did you open the spark gap to 0.7 mm ~ 0.8 mm (0.028" ~ 0.031".) To take advantage of the better coils?

I did mine, and didn't notice any ill effects,.
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Old February 21st, 2016, 06:36 PM   #6
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There is no real reason to do this.....other than to say you've done it. Maybe to save a few ounces over the factory coils.

You will not gain anything. However, you will also not lose anything.

It's a trick mod though and something I didn't know was possible.
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Old February 21st, 2016, 07:25 PM   #7
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Better, stronger spark, then the OEM coils, which allows you to open the plug gap up a little bit more and eliminating the OEM caps which are sometimes prone to problems, needing to be disassembled, cleaned renew the HT leads.
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Old February 21st, 2016, 07:54 PM   #8
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Thanks. I am definitely doing this.
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Old February 21st, 2016, 08:11 PM   #9
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Quote:
Originally Posted by RacinNinja View Post
There is no real reason to do this.....other than to say you've done it. Maybe to save a few ounces over the factory coils.

You will not gain anything. However, you will also not lose anything.

It's a trick mod though and something I didn't know was possible.
A dyno would likely not tell the difference, but all the people making money selling aftermarket sparkplugs and coilpacks would say that the stronger spark would lead to increased HP, and better fuel economy. IRL, all it likely does is make you feel better about yourself.
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Old February 21st, 2016, 08:17 PM   #10
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And it cleans up the coils/valve cover area.

Drill that spot weld to take the old coil mounts off of the front engine mounts, then you have space to take the valve cover off without removing anything else. If you've got small hands, you just made valve clearance checks easier.
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Old February 21st, 2016, 08:19 PM   #11
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Quote:
Originally Posted by HoneyBadgerRy View Post
A dyno would likely not tell the difference, but all the people making money selling aftermarket sparkplugs and coilpacks would say that the stronger spark would lead to increased HP, and better fuel economy. IRL, all it likely does is make you feel better about yourself.
This. I could see this being beneficial with higher compression or adding a turbo.

One thing that just crossed my mind though, OP: What is the resistance across the leads for this vs the factory coil? Less resistance = possible CDI damage, more resistance = less spark. Did you happen to measure them against the factory coils?
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Old February 21st, 2016, 08:30 PM   #12
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The resistance is less, I didn't measure it, there's plenty of information already done. I know @InvisiBill has done research on this matter, and he also runs the CoPs.

Some of the information out there does mention adding resistors, but no definitive answer on that point, so I just plugged them in.

I ran this set-up all this past season with no ill effects whatsoever.
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Old February 21st, 2016, 08:50 PM   #13
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@alex.s did the modification awhile ago, Thxs to his post I did this.

Zx coil over plugs
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Old February 21st, 2016, 10:02 PM   #14
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Quote:
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The resistance is less, I didn't measure it, there's plenty of information already done. I know @InvisiBill has done research on this matter, and he also runs the CoPs.

Some of the information out there does mention adding resistors, but no definitive answer on that point, so I just plugged them in.

I ran this set-up all this past season with no ill effects whatsoever.
Cool, thanks! My curiosity is peaked. Mods like this are illegal in our racing club but if they do away with the stock 250 class I may consider this, for nothing more than a few ounces of weight.
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Old February 21st, 2016, 10:10 PM   #15
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There are more advantages than just saving weight, if that was my reason I'd go on a diet LOL

But seriously, it's taking advantage of advances in technology like other bikes have done.

I like this modification, update so to speak, better spark, less to go wrong, cleaning up the engine, and it's cheap and easy enough to do, like my prom date
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Old February 21st, 2016, 10:16 PM   #16
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Quote:
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There are more advantages than just saving weight, if that was my reason I'd go on a diet LOL

But seriously, it's taking advantage of advances in technology like other bikes have done.

I like this modification, update so to speak, better spark, less to go wrong, cleaning up the engine, and it's cheap and easy enough to do, like my prom date
Well, maybe I'm just super lucky but I've got bikes that are over 40 years old, with points, coil and condenser that are all original that have never failed. I have never had a coil nor wire nor cap fail.

Hell, the bike I race regularly has one wire from the alternator to the points, kill switch and coil. No muss, no fuss!
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Old February 21st, 2016, 10:29 PM   #17
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I can understand your point, some riders here never even seen a set of points, unlike us older riders.

I have fond memories of my 64 GTO which among other modifications I had a Mallory dual point.
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Old February 21st, 2016, 10:32 PM   #18
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I can understand your point, some riders here never even seen a set of points, unlike us older riders.

I have fond memories of my 64 GTO which among other modifications I had a Mallory dual point.
You calling me old???!?! BAHAHAH! The bikes are older than I am by a bit.

I'm not offended, merely pitching some poo. However, I will agree that points and carbs are a lost art. I'm one of the few "younger" folk that still play with and understand these archaic systems.

And those old Mallory systems were pretty trick. How many people here know what dwell is and why it's important??
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Old February 21st, 2016, 11:19 PM   #19
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Or setting the point gap with a matchbook cover.

The Mallory set-up was trick and a PITA to set, but once you had it all set, it was an awesome set-up.

In the days of GM HEI was all the rage, I keep my Mallory, along with my Q-jet
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Old February 22nd, 2016, 12:23 AM   #20
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FYI the resistance of external coils is 3ohm, the CoP's are 1.5ohm, I worried about this when I fitted CoP's to my 800 4 years & a good few thousand miles ago. So I tested a CoP in place after a long run, the CoP is inside the plug tunnel so does not get cooled & they are designed to run like that. I got 2.5ohm resistance whilst hot after the few minutes it took me to get access ! No CDI or ECU damage.

Head access was my main reason for doing this & I'll be fitting a big bore 282cc later in the year.
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Old February 22nd, 2016, 07:21 AM   #21
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Quote:
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FYI the resistance of external coils is 3ohm, the CoP's are 1.5ohm, I worried about this when I fitted CoP's to my 800 4 years & a good few thousand miles ago. So I tested a CoP in place after a long run, the CoP is inside the plug tunnel so does not get cooled & they are designed to run like that. I got 2.5ohm resistance whilst hot after the few minutes it took me to get access ! No CDI or ECU damage.

Head access was my main reason for doing this & I'll be fitting a big bore 282cc later in the year.
0.5 ohm difference is no big deal for sure!

Dropping it from 3 to 0.5 ohm would be a not so good thing.
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Old February 22nd, 2016, 07:53 AM   #22
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It's cheap and easy enough to do, like my prom date
you still have her number by chance?
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Old February 22nd, 2016, 08:09 AM   #23
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Unfortunately not, but I think I still have the receipt

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Old April 16th, 2016, 02:18 PM   #24
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FYI the resistance of external coils is 3ohm, the CoP's are 1.5ohm, I worried about this when I fitted CoP's to my 800 4 years & a good few thousand miles ago. So I tested a CoP in place after a long run, the CoP is inside the plug tunnel so does not get cooled & they are designed to run like that. I got 2.5ohm resistance whilst hot after the few minutes it took me to get access ! No CDI or ECU damage.

Head access was my main reason for doing this & I'll be fitting a big bore 282cc later in the year.
I'm not sure if the 250 is the same, but the 500 coils are considered in spec down to 2.2-2.3Ω (I measured my low-mileage '09 coils and CoPs at the same 3Ω and 1.5Ω). If the Ninjette coils are similar, then the CoPs up to temp are actually completely within spec.

Our igniters on the 500 seem to be pretty black-box, so I don't know exactly what components are inside them. But from my basic understanding of how a CDI system works, I don't think there's much in the circuit that would even be affected by a slightly lower impedance CoP anyway. Obviously closer to spec is better, but I came to the conclusion that I wouldn't really be hurting anything.

Mine are still going great. My only related plans are to add some supports for them, since the 500's plug wells are much more open than the 250's.
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Old April 16th, 2016, 03:35 PM   #25
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I have no ill effects to report either, all is well with the CoPs and the IGN module.
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Old April 16th, 2016, 03:40 PM   #26
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you still have her number by chance?
Hmmm....
Indiana & Kentucky are next to each other...
....it is conceivable she is your mother ....and he your real dad!
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Old April 16th, 2016, 04:06 PM   #27
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Hmmm....
Indiana & Kentucky are next to each other...
....it is conceivable she is your mother ....and he your real dad!
Knowing my mother, yes.

Knowing me and my dad, no.
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Old April 16th, 2016, 04:12 PM   #28
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All of the children I have fathered are all accounted for.
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Old April 16th, 2016, 04:16 PM   #29
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All of the children I have fathered are all accounted for.
How do you know there was no condom leakage though.
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Old April 16th, 2016, 04:17 PM   #30
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^ what the hell kind of forum have I joined here?
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Old April 16th, 2016, 04:26 PM   #31
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A father knows......
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Old April 16th, 2016, 04:27 PM   #32
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^ what the hell kind of forum have I joined here?
My bad, if I remember I invited you
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Old April 16th, 2016, 05:00 PM   #33
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^ what the hell kind of forum have I joined here?
An awesome one.
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Old November 3rd, 2016, 08:50 PM   #34
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Good stuff here - Thanks for the write-up!
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Old November 3rd, 2016, 10:46 PM   #35
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MOTM - Jun '17, May '16, Mar '15
Glad you enjoyed it, I'm happy to say that the upgrade is still working great.

I personally recommend this upgrade.
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Old November 4th, 2016, 12:57 AM   #36
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I'd just like to point out that there appear o be differences in the ignition system of the Ninjette & the ZZR250 that I have. The Cops work for a while, but overheat the igniter on my ZZR such that the ignition gives up. I spent ages working on this then swapped back to the original high output coils & the issue went away.
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Old November 20th, 2016, 09:04 PM   #37
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An awesome one.
:rofl1
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Old September 6th, 2017, 10:58 AM   #38
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turned out great. i used high temp glass tape and heat shrink on top.
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Old September 7th, 2017, 04:59 PM   #39
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Looks good, don't forget to open the plug gap to take full advantage of the hotter coils.
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Old September 7th, 2017, 09:23 PM   #40
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i'm at .030. this mod is well worth it.
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