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Discussion Starter · #1 ·
I've got the ever-present problem of the ignition coil packs not budging from my 2006 er6n. Have been using a good penetrating oil over the course of a week and still not budging. Have broken the top off the left one in the process and damaged the other. Replacing them doesn't bother me, as long as I can get them out!

Would piloting a drill hole and screwing down into it for leverage be an option? Or you I go straight to removing the cylinder cover and trying to pry them out from there?

Cheers in advance
 

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If it's seized to the plug, removing the cover might not work that well. I'd try to wedge something (spray tube, pick, coat hanger, etc.) down between the cover and the boot to get the penetrating oil deeper into the hole. Do this in a few places and then see if you can get the boot to twist.
 
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I've got the ever-present problem of the ignition coil packs not budging from my 2006 er6n. Have been using a good penetrating oil over the course of a week and still not budging. Have broken the top off the left one in the process and damaged the other. Replacing them doesn't bother me, as long as I can get them out!

Would piloting a drill hole and screwing down into it for leverage be an option? Or you I go straight to removing the cylinder cover and trying to pry them out from there?

Cheers in advance
What Green said, although i think with valve cover off maybe the best way to go to pull them out as they stick out a fair bit, and you might pull them out with the cover (if it's stuck to the cover and not the plug) but you have to be extremely careful not to drop any rubble into the valvetrain. Other than that, it's honestly just wish you the best of luck lol
 

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Discussion Starter · #4 ·
If it's seized to the plug, removing the cover might not work that well. I'd try to wedge something (spray tube, pick, coat hanger, etc.) down between the cover and the boot to get the penetrating oil deeper into the hole. Do this in a few places and then see if you can get the boot to twist.
Good shout. I've been trying to pick away at the rubber to get better access with the spray, I think it is going to be one of those 'patience required' jobs that will just take a bit of time a calm approach! Haha
 

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Discussion Starter · #5 ·
Valve cover off maybe the best way to go to pull them out but you have to be extremely careful not to drop any rubble into the valvetrain. Other than that, it's honestly just wish you the best of luck lol
Haha cheers. Yeah.... I'm not enjoying it to be honest but hey ho, I'll just keep plugging away and hope for the best
 

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Discussion Starter · #7 ·
Haha cheers. Yeah.... I'm not enjoying it to be honest but hey ho, I'll just keep plugging away and hope for the best
Also, I know what the haynes says but I've had conflicting responses from more "relaxed" DIY mechanics, but, replace the gasket and reseal or clean up the surfaces/gasket and reseal?
 

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Also, I know what the haynes says but I've had conflicting responses from more "relaxed" DIY mechanics, but, replace the gasket and reseal or clean up the surfaces/gasket and reseal?
I used a bit of sealant and not a drop of oil for 10k miles. It's fine, and mine was fairly old when i took it off. Clean gasket, if it doesn't come away from one or the other surface, perfect, if it kinda hangs between both, take it off, clean it up, thin layer of silicone sealant, job done. Be sure to not go too much on the sealant though as it's not good if it gets pressed out the sides into the cylinder head.
 

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Discussion Starter · #9 ·
I used a bit of sealant and not a drop of oil for 10k miles. It's fine, and mine was fairly old when i took it off. Clean gasket, if it doesn't come away from one or the other surface, perfect, if it kinda hangs between both, take it off, clean it up, thin layer of silicone sealant, job done. Be sure to not go too much on the sealant though as it's not good if it gets pressed out the sides into the cylinder head.
That's what I had in mind. Cheers bud
 

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I used a bit of sealant and not a drop of oil for 10k miles. It's fine, and mine was fairly old when i took it off. Clean gasket, if it doesn't come away from one or the other surface, perfect, if it kinda hangs between both, take it off, clean it up, thin layer of silicone sealant, job done. Be sure to not go too much on the sealant though as it's not good if it gets pressed out the sides into the cylinder head.
^^^ This
 
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Hey MFTZ13, I had this problem on my 2010 er6f and i can confirm that removing the cover is infact the solution. It is a bit fiddly but it is doable.

Here is a pic of what it looked like on the other side.

View attachment 139581

On this, if you get replacement plugs, get some from the newer Z650s or the Newer ER6s that don't have that stupid dumb cover in the middle. That cover is made out of steel, it rusts and expands causing the coils to jam in the head cover. The newer ones don't have this cover and instead have an aluminium body that's thin in that part, they are completely compatible, I run 2017 Z650 coils in my 2011 ER6.
 

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Discussion Starter · #14 ·
Hey MFTZ13, I had this problem on my 2010 er6f and i can confirm that removing the cover is infact the solution. It is a bit fiddly but it is doable.

Here is a pic of what it looked like on the other side.

View attachment 139581
Cheers bro. I finally got there! Now just waiting for a new gasket to arrive to put it back together!
 

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Discussion Starter · #15 ·
On this, if you get replacement plugs, get some from the newer Z650s or the Newer ER6s that don't have that stupid dumb cover in the middle. That cover is made out of steel, it rusts and expands causing the coils to jam in the head cover. The newer ones don't have this cover and instead have an aluminium body that's thin in that part, they are completely compatible, I run 2017 Z650 coils in my 2011 ER6.
Cheers. I ordered some later ones so hopefully they do the job. Also suggested to me in other forums to apply a little copper grease, what you reckon?
 

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Cheers. I ordered some later ones so hopefully they do the job. Also suggested to me in other forums to apply a little copper grease, what you reckon?
No, absolutely not copper grease!! Get white silicone dielectric grease or lithium grease instead, you want insulation and waterproofing, the copper grease will react with the aluminium and cause nasty oxidation, especially with all the heat around. Put the grease around the rubber boots both on the top and the bottom, but not in the connections.
 

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Discussion Starter · #17 ·
No, absolutely not copper grease!! Get white silicone dielectric grease or lithium grease instead, you want insulation and waterproofing, the copper grease will react with the aluminium and cause nasty oxidation, especially with all the heat around. Put the grease around the rubber boots both on the top and the bottom, but not in the connections.
Nice one, cheers
 
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