Ignition coils

[Silver]

I need a new set of coils as all 4 of mine do not click down tight any longer (11,000 miles on my 04 warrior) I found a set off of an 02 R-1 I'm 90% sure they are the same can any one confirm this for me.Also any fixes out there for the coils.Mine are so bad last yr when hitting large bumps I would get a miss from the coils jumping up and down.In case your wondering yes I put new plugs in every year so it is not because of the threads being woren out.Thanks Mike

 

[LazyBastard]

If the clip is worn badly, then there may not be anything you can do about it. If they're just dirty, then you might be able to clean them with a harsh solvent. What leads to this is that the top of the coils don't seal well to the rocker cover, allowing them to shake around. You'll note that the top of the coil is a rubber seal -- just way too thin. Put a nice big o-ring under that seal to tighten it up, if not to save the existing coils, then at least to protect the new ones.

Regarding the coils off the 02R1, the parts catalog shows different part numbers, but by the way they are drawn, it appears to be a matter of just the rubber parts. Note that the 04 uses a revised coil compared to the 03, which is indicated by a revision number for the 04 part number.

The part numbers are as follows;
02R1: 5PW-82310-00-00
03RX: 8FA-82310-00-00
04RX: 8FA-82310-01-00

Now I know that the 03 and 04RX are definitely compatible, but if you can, you might want to check the resistances off the 02 and compare.




Final thought... If memory serves, the revision made for the 04 coil is to use a solid end cap on the plug. That would mean that you need to screw end caps onto the plugs rather than just leaving the threaded end exposed. I say this because when you say "threads worn down", it leaves the impression that you are plugging the coil directly onto the plug threads, which wouldn't fit correctly.

 

[Rockmeister]

Read on here about using Ford coils and also using a spring on the top of the plug to make up the slack.

Am looking into both solutions as I have the same problem.

 

[Silver]

LB, Aren't these coils designed not use the soild end caps.My sled brand new didn't have soild end caps.I have not tried it to see if it works but will.I bought the 02 r-1 coils this morning and will use an O-ring like you sugest.I bought a r-1 coil for my YZ 426 and it was the same except the rubber seal as my Warrior.I did try the little spring on top worked okay in a couple but not all of them.Makes me wonder if these stick coils are that much better then conventional coil and plug wire never had issue with old style.Thanks guys for your help.Mike

 

[Black 1000]

I have 05 coils in both my 03's and run the plugs with not top caps. Run perfect even with the juice

 

[Indy]

05 coils in my 03, work fine.

 

[Len Todd]

I do not recall plug tip caps on my '04. Guess I'll have to look when I get up up there. But LB is right, the '04 had a revised connector to the plug.

The coils fit very tight in the valve cover. If they are moving around, it is the rubber that holds them in place that could be the more significant problem. The O-Ring will help with that.

Do not forget to check them for arcing by removing the rubber ring and reinstalling in a dark room. Then start it up and look for arcing. If they are arcing they need to be cleaned. If they are still arcing after cleaning, then they need replacing.

 

[Silver]

I ended up buying a set off an R-1 street bike .Way cheaper price$ 40 bucks for coils (4) .Best price I saw here was $40 each and they are the same coils.

 

[rxwarrior]

Just bought new coils for my 04 Warrior and they DO NOT take the cap on the spark plug.

 

[Rockmeister]

My '05 Warrior does NOT take the cap on the plug either.