Cracked Stick Coil Casings
A number of owners have reported that after a period of engine rough running or during spark plug inspection/replacement they have discovered cracks in the plastic casing of the Stick Coils. Stick Coils are a combined ignition coil and spark plug cap.
The consensus is that the Stick Coils (Kawasaki P/N 21171-1286) appears to have cracked due to heat damage, however it is also likely that it is due to internal corrosion. There is often evidence of moisture ingress and rust on the Stick Coils during removal and some owners recommend fitting with a smear of silicone grease around the rubber seal to enhance sealing. Some owners who discovered this issue during servicing and not had a rough running issue have carried out a temporary repair to the Stick Coil using High Temperature RTV to fill the crack.
From internet forum posts the following repair procedures may work: The corroded metal sheath can be removed by firstly pulling the rubber boot seal off the bottom of the coil then removing the cracked plastic sleeve. The corroded metal sleeve can then be cleaned up and treated with ?rust kill? or replaced with some aluminium foil as it is probably required for EMI suppression. The plastic sleeve can be replaced by wrapping with electrical or self annealing tape or repaired using Araldite or High Temperature RTV to fill the crack.
The other problem is that if the stick coil is left in the motor for too long after it has split it becomes very difficult to remove. There are reports from a dealer who discovered this issue during a service and it necessary to remove the entire motor to extract the coils.
The only way to get around this issue to keep taking the coils out to check them. Do it regularly and you should be able to spot a split as it forms and prevent the real grief of getting it stuck. Again consider using a non-conductive grease on the exterior of the stick-coils when refitting especially around the rubber seal.
Both the primary and secondary windings of the Stick Coil can be tested using a multimeter as follows:
Primary windings (A) should be 1.1 to 1.5 ohms. Secondary windings (B) should be 10.8 to 16.2 kilo-ohms (10800 to 16200 ohms).
Kawasaki advise that the original Ignition Coil Assembly P/N 21171-1286 has now been superseded by P/N 21171-0028, hopefully this is an improved product to overcome this failure.
Kawasaki use Nippon Denso coils, the Kawasaki P/N 21171-1286 is a Denso P/N 129700-4580, and P/N 21171-0028 is a Denso P/N 129700-5350. The primary windings for both these parts are 1.1 to 1.5 ohms. The secondary windings (coil windings - top pin to plug) are 10.8 to 16.2 kilo-ohms. Any stick coil meeting these characteristics and having the correct physical dimensions should work OK as a replacement.
These are relatively costly items so those looking for second-hand (used) replacements can also use Stick Coils fitted to the following Kawasaki models as follows:
Kawasaki.com list P/N 21171-1286 fitted to the following:
ER650A6F (ER-6n (Australian)) (2006)
ER650A6S (ER-6n (European)) (2006)
ER650A7F (ER-6n (Australian)) (2007)
ER650A7F (ER-6n (European)) (2007)
ER650A8F (ER-6n (Australian)) (2008)
ER650A8F (ER-6n (European)) (2008)
ER650C9F (ER-6n) (2009)
ER650CAF (ER-6n) (2010)
EX650A6F (Ninja 650R) (2006)
EX650A7F (Ninja 650R) (2007)
EX650A8F (Ninja 650R) (2008)
EX650C9F (Ninja 650R) (2009)
EX650CAF (Ninja 650R) (2010)
KLE650A7F (CANADA ONLY) (2007)
KLE650A7F (Versys (European)) (2007)
KLE650A8F (Versys (European)) (2008)
KLE650A8F (Versys) (2008)
KLE650A9F (Versys (European)) (2009)
KLE650A9F (Versys) (2009)
ZR1000-A1 (Z1000) (2003)
ZR1000-A1H (Z1000 (European)) (2003)
ZR1000-A2 (Z1000) (2004)
ZR1000-A2H (Z1000 (European)) (2004)
ZR1000-A3 (Z1000) (2005)
ZR1000-A3H (Z1000 (European)) (2005)
ZR1000A6F (Z1000 (European)) (2006)
ZR1000A6F (Z1000) (2006)
ZR1000B7F (Z1000 (European)) (2007)
ZR1000B7F (Z1000) (2007)
ZR1000B8F (Z1000 (European)) (2008)
ZR1000B8F (Z1000) (2008)
ZR1000B9F (Z1000 (European)) (2009)
ZR750-K1 (Z750S) (2005)
ZR750K6F (Z750S) (2006)
ZR750L7F (Z750 (Australian)) (2007)
ZR750L7F (Z750 (European)) (2007)
ZR750L8F (Z750 (Australian)) (2008)
ZR750L8F (Z750 (European)) (2008)
ZR750L9F (Z750 (European)) (2009)
ZR750LAF (Z750 (European)) (2010)
ZR750LAS (Z750 (European)) (2010)
ZX1200-B3 (Ninja ZX-12R) (2004)
ZX1200-B4 (Ninja ZX-12R) (2005)
ZX1200B6F (Ninja ZX-12R (European)) (2006)
Kawasaki.com list P/N 21171-0028 fitted to the following:
KLE650CAF (Versys) (2010)
ZR1000DAF (Z1000) (2010)
Owners report that a Mitsubishi stick coil P/N F5T560-5323 can also be used.