Join Date: Nov 2008
Location: Kitchener Ontario
MK-2 Service manual
drawing 16-45 , the stick coils are powered by the ECU, MK-2 and MK-1 bikes have had stick coils crack and fail, I use dielectric grease around the upper seal, which helps to prevent seizing, some members had great difficulty in getting them out. Since you say everything else is OK, I would look there, once you produce a high voltage tracking, it is impossible to get rid of. Remember a spark or arc is hotter than the surface of the sun, it will etch into porcelain. You may have ignition but the primary may be tracking to ground or you could also have shorted primary turns of the stick coils which would eventually cause the ECU fuse to blow .
A second thing to look at is the harness on the right side, near where the clutch cable enters, several have had the tank rubbing on the harness and a bare spot, the stick coils I think enter from the right side harness. While at it look closely at the left side harness, on my 2015 I used something like 6 of the 100 lb wire ties as my harness was so tight I couldn't get the air box out without prying it out and impossible to get back in. FYI the air box is plastic so no worries as to shorts there. The MK-2 which is what yours is, has plenty of wire and it wasn't until the MK-3 came along that Kawasaki started shortening the wire lengths on the bike. My right side front signal wire/ headlight low and high was so tight it rubbed on the center headlight assembly brace, I extended it six inches.
Last edited by onewizard; 06-28-2019 at 10:41 AM.