Chasing Gremlins... Spark Cap Fail Trials and Tribulations

[DC]

Bake,

Great info!  Makes me want to go and check my plug caps, plugs, etc.

[David Baker]

pcarrell,
Yes I have two bells... They're mounted on the frame just below the crash bars... One on either side, Cause I like balance in my life. LQTM

[pcarrell]

Are you running a Gremlin bell?  Maybe that was the real root of the problem!

[David Baker]

Roger That Reo...
I completely forgot to add that I had to disconnect the ECU to clear the code for all the malfunctions, Good point! According to the Kawi Dealer I could just unplug the ECU for a while and didn't have to unhook the myriad of wires servicing all the things hooked up to the battery (really not that much, LED's, Tender, Amp for Speakers)

[ChilliDrift]

Thanks for the info...

[49Reo]

Good article, Bake, thanks for that. Sometimes, when something "upsets" the "electronic brain" (sorry, having a gray moment, and can't think of its technical name), you have to disconnect the battery in order for it to clear fault codes. I had something similar this spring when I ran Beauty out of gas; it wouldn't start, kept backfiring, flooded severely. Pulled the plugs, spun it over until the gas (lots of it too) quit spewing out of the plug holes, dis-connected the battery for an hour while I had lunch, hooked it back up, ran perfectly.

Regards and such,
49Reo

[David Baker]

Hope this isn't too windy.

Thought I'd share in the event this should happen to anyone else. I've read similar posts regarding popping/backfire/rough running but not to this specific problem.

Back in the beginning of Nov. while meeting up with some other riders for a Charity Run the bike developed a hesitation/spitting/popping as if it wasn't getting fuel or spark. Fortunately I had a similar problem when I first purchased the bike which gave me starting point. Many of you may be aware that Kawasaki uses the same style plug cap on the Vulcan as they do on their snowmobiles (the wire screws into the cap) I checked to see if the connections were loose. In the process I discovered that the RF/Cap was cracked and not making connection. I called the local Kawi Dealer to see if they had any plug caps in stock as it was on the way, They were out of stock being this late in the season, They suggested trying to wrap it with tape which I did, Asked if running it with just three plugs firing could damage anything and they said other than wasting fuel it shouldn't. They were right about the fuel, Went through a full tank on a 37 mile ride. By the end of the ride it seemed worse, With the fuel light on I reached home and put her away and waited for the parts to come in. I ordered replacements for all four caps. Parts guy at dealership said NGK makes them and they're only $5.00 each as opposed to Kawasaki's $20.00 (no-brainer)

Three days later, Parts in, Installed on bike, Problem solved... "Hold on there Baba Looey"

This is where the cold antiseptic sting of reality sets in... Fired the bike up and headed out to get fuel (less then a 1/4 mi away) Started all over again, Literally coasted in to get fuel, Fought me to start, Limped it home, It fought like it was running on one cylinder. FYI... Never... I mean Never! Run the bike empty!

Due to running with three plugs firing the EFI was calling for more fuel, That caused the remaining plugs to carbonize (I'm not talking a little bit) Add to that picking up nasty no goods from the bottom of the tank along with clogging the fuel filter and injectors needless to say I did me some tearing down. Bags, Seat, Tank etc. Flushed the fuel filter and lines, Added new plugs, Threw in some injector juice, Reassembled crossed my fingers and fired it up... I'm grateful this solved the problems... Lesson learned. I believe I read a quote from "Chief" "The best lessons learned are the ones that don't cost too much" I got away pretty lucky... Between plug caps/plugs and injector juice right around $45.00 Hope this helps someone else in the future.
Thanks for letting ramble, Bake.