Hi. Just posting this on the off chance anyone can offer any advice or banter to cheer me up over trying to remove a stuck ignition coil.
Coils have never been removed and in place for 27k miles and I need to remove them to do a valve check.
One of them eventually but reluctantly pulled out after an attack of mole grips, brute force, swearing and a drowning of wd40. The other i swear has been stuck in there with teflon. The coils casing has probably cracked from expansion making it a tight fit but I just can't get it to budge at all, in any direction. I've even resorted to trying to pry the coil up with a tyre lever, yeah I'm desperate. Bike is in garage and the coil has been sprayed again with wd40 for sitting over night, again. I don't know how to get this out and what to try next, especially now that much of the top part of the coil that could be gripped has worn away from many, many unsucessful attempts.
Anyone have any ideas that will help? Or am I looking at engine removal and taking the lump into a garge for help, if they would be able to help given what's left of the coil tip?
A difficult one yiddle678Would need no know what bike and the type of coils fitted.
I am trying to picture what you have. Are they conventional cyclindrical aluminium coils and do they fit into a tight space etc,
As it appears the coils are now defunct, would it be possible to fillet the inside of the one that is stuck and then push the now empty casing in toward the centre. Maybe that will give enough movement to free it up completely. Engine out seems a bit drastic.
I hope you have more joy on your next attempt.
If you have ali to ali with corrosion in between the mating surfaces and a close fit. It is always difficult to free up because the ali oxide expands. But as JP said try PLUSGAS or similar and keep apply over a few days before you try again.
Thanks JP for the plusgas tip, a product I never knew about! I'll try this first..
And thanks for the fillet suggestion David. Yes the coil is now defunct. I assume this involves using a regular drill piece to drill away the inner coil material to be able to push the casings towards center? I do have working space with engine in place to attempt this, although I will be drilling at a slight angle.
A bit more info on what I have:
Bike is a er6 and the coils have never been removed. They are stick-type ignition coils and I think this coil like the other has split its plastic casings. The coil is constructed with a metal sheath around
it and a plastic sheath over the top of it. Looking at the coil I was able to remove, it's the plastic one that
cracks and splits as the metal sheath rusts and expands. At at the very top of the coil but below the lead connection tip and inside the engine casing is a much shorter rubber sheath for weather protection so I'm going to need to remove as much as I can of this for the plus-gas to penetrate or maybe I won't given that water/condensatiion has I think got in there somehow to create this rust and expansion...
In line ones can be a pain, your going to have to destroy them now to get them out and fit new ones, it may damage the plugs so expect to fit new ones too and as JP says grease the out sides
Having spent most of the day fighting to get this stuck coil out I have succeeded! It is out albeit in lots of small pieces. It took some effort and I had to drill it out but couldn't get good position with the drill piece so had to take the drastic action of dropping engine from the frame. Doing this meant that I could also move the head of the engine case to help free up the coil.
Just got to put the bike back together! oh and get some new coils and then I can get back to what started all this to check the valves. I have been looking into the cost of new coils and luckily I was sitting down when doing this. 1 coil can cost £80-£110!
A tip for er6 owners in the same position. I'm happy to replace with good usable second-hand coils but I've not had any sucess with breakers for the ER6. I started to look at different kawasaki models that might share the same coil basing the assumption on part numbers. Z1000 2004-9 coils are an exact match. I've ordered 4 second-hand ones of net for £40. Bargain! I will be taking out the coils at every service and applying grease from now on. Thanks for the helpful replies in this thread!
yiddle678 It looks like a case of, if at first you don't succeed, hit it with a big hammer lol
Seriously I am glad you are making progress, good luck with the rest of the job
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