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Post by oneleggedbiker on Jul 11, 2019 11:05:53 GMT -6
So, I've been working on an '89 EN450 bobber build. I've recently started the reassembly process. And, I'm hoping you guys can shed some light on one of my concerns. I opted to go with a new tank and on mock up noticed it was hitting the top of the ignition coils. I DO NOT want to do a tank raise so I figured I could relocate the coils. Then when looking at the wiring schematics I noticed that the coils have a ground indicator. Do the coils ground to the frame at their stock mounting location? I'm going with my better judgement and assume the answer is yes. If that is the case has anyone relocated their coils? Is there anything that would prevent me from u-bolt mounting them to the front down tubes on the frame with a crimp on post connector and then running it to a frame ground? Any insight will be greatly appreciated. I've included a couple pictures of the build so far.
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Post by bikeman on Jul 11, 2019 14:30:11 GMT -6
why not do away with the coils altogether. and fit a set of COPS [coil over plug] many bikes use them from the CBR to the ZZR. easy fit just remember the left side [as sat on bike] uses the green coil wire.
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Post by oneleggedbiker on Jul 13, 2019 10:33:00 GMT -6
why not do away with the coils altogether. and fit a set of COPS [coil over plug] many bikes use them from the CBR to the ZZR. easy fit just remember the left side [as sat on bike] uses the green coil wire. , is there anything specific I need to keep in mind doing COPS??? Do all COPS follow the procedure on the COPS thread here? I remember reading it and will be going back to read it again. It seemed in the original thread there were concerns about the size of resistor used due to heat... |
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Post by bikeman on Jul 14, 2019 5:32:46 GMT -6
I think it depends on who you believe, I bought a full set of COP's with harness off a ZZR600 for my two bikes [EX500's] the stock coils resistance was 2.75oms the COP's were 1.25oms. so on one bike I fitted 1.5oms resistors to bring them in range of the stock ones. on the other bike I left off the resistors and just fitted bare COP's. two years on there is no discernible difference in the way the bikes run if anything the one without resistors seems to start better and run smoother. but this could be due to the bikes rather than how the COP's were fitted.
you will need the connecting wires for the cops they are quite long so can be cut down if you fit 16amp spades to the end there is no need to alter the bike wiring just connect them to the coil wires. just make sure you get the wires correct or the bike wont start.
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Post by oneleggedbiker on Jul 22, 2019 12:57:22 GMT -6
bikeman I went ahead and pulled the trigger on doing the COPS upgrade. I got my COPS from RMStator due to poor Ebay descriptions and lack of information being presented. Plus, I've used RMStator stuff before and it's always been quality. I did purchase the harness off of Ebay for the connectors knowing any wiring can be fixed (although it looks to be in great shape). I went ahead with stuff for a 2000-2002 ZX-6R/2005-2008 ZZR600 as well as looked up service manual coil specs. My questions now are concerning resistors... I understand that I want a 25w or 50w resistor. I also understand I want it to fall into the spec of the bike. I was thinking I should wait until the coils show up before ordering resistors. That way I can get an actual reading on the new coils. But, like most people I'd like to be able to start the upgrade when the coils and harness show up. I was thinking I could just order two 1 ohm and 1.5 ohm resistors. Do you see any error in my ways here? Also, concerning resistance... I understand I want the primary to fall into my original specs. The stock EN450 primary resistance specs 2.1-3.2 ohms, the ZX-6R/ZZR600 primary resistance specs 1.2-1.6 ohms. The secondary resistance on a stock EN450 specs 10k-16k ohms and the ZX-6R/ZZR600 specs 8.5k-11.5k ohms. Is the secondary resistance spec something I need to focus on as well?
I included a parts list and links for what I've purchased minus the resistors pending your thoughts in that area. Is there anything I'm missing?
Parts List (2) COPS Coils Kawasaki OE# 21171-1272 RMStator #RM06083
(1) Coil Sub-Harness Kawasaki OE# 26030-1706
(2) 25w 1.5 or 1 ohm Resistors (waiting for the new coil specs) |
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Post by bikeman on Jul 22, 2019 14:48:19 GMT -6
yep all that's stuff's fine. almost identical to ones I got but mine were a lot cheaper [and older] as I got them of flea-bay. fair enough I knew what to get though.
those resistors are exactly the ones I got. 50w 1.5ohm you need to wire them into the positive side of the coil as this is the wire the CDI senses. to be absolutely sure you should check the resistance of both the stock coil [to get a base line] then the cop's to find the difference. to be honest mate it's not that critical, just belt and braces sort of thing my old gen 1 runs fine without them. if you really want to get them early probably the 1.5's are the ones to get. assuming the 454 stock coils are the same as the EX ones.
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Post by oneleggedbiker on Aug 17, 2019 10:12:03 GMT -6
So, I finally got around to soldering up my COPS upgrade. For anyone interested or doing a custom tank that hits the OE coils. This is the OE coil and the COPS side by side. I'm going to build a small mounting plate to mount the resisters on. I'll follow up when they are on the bike. bikeman thank you for your patience and answering my questions.
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Post by bikeman on Aug 18, 2019 16:52:18 GMT -6
your welcome. glad to be of help. that looks a nice neat job. when you fit the COP's they may feel a little slack/wobbly, because they are so long. don't worry it is not an issue. some on the EX forum fit a sort of bracket for them to go through attached to the square head plates. never bothered myself it just depends on how professional you want the conversion to look. me I'm not bothered there hidden under the tank.  |
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