2003 R6 Firing Problem - Wrist Twisters
 
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post #1 of 7 Old 10-07-2009, 07:07 AM Thread Starter
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2003 R6 Firing Problem

My cousin bought a 2003 Yamaha R6 earlier this summer. Last week he told me it wasn't running right and wanted me to look at it. He brought it over on a trailer Monday and dropped it off. I started it and found that it was not running on all cylinders. A quick touch to the pipes confirmed that the number 2 cylinder was not firing but all the others were.

My first thoughts were spark plug or coil. It took almost 2 hours of labor (following the factory service manual) to get to the plugs. The seat, tank, airbox, intakes, and engine heat shield had to be removed. Below is a picture with everything except the heat shield removed.



I found what appears to be the problem. Each cylinder has its own coil. On the problem cylinder, there is a hole in the side of it where it looks like it shorted out. The hole through the rubber boot is charred looking.

My question is this...Did the coil fail on its own or is there an underlying issue?

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post #2 of 7 Old 10-07-2009, 07:18 AM
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Quote:
Originally Posted by cmurphy84 View Post
It took almost 2 hours of labor (following the factory service manual) to get to the plugs. The seat, tank, airbox, intakes, and engine heat shield had to be removed.
Geez... #3 spark plug doesnt seem so bad anymore...

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post #3 of 7 Old 10-07-2009, 07:20 AM
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i'm betting it was a defect from the get go.......... a hole burned in the side is not a normal failure.... was the coil mounted solid? or did it appear something had come into contact?

if it was solid and non-moveable i would write it off to defect... replace it and put her back together....

IMHO



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post #4 of 7 Old 10-07-2009, 07:21 AM
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Quote:
Originally Posted by Basspiece919 View Post
Geez... #3 spark plug doesnt seem so bad anymore...
i dunno... i can't even see the engine on my bike without peeking thru a hole in the fairings....lol



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post #5 of 7 Old 10-07-2009, 08:09 AM Thread Starter
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Quote:
Originally Posted by barton664 View Post
i'm betting it was a defect from the get go.......... a hole burned in the side is not a normal failure.... was the coil mounted solid? or did it appear something had come into contact?

if it was solid and non-moveable i would write it off to defect... replace it and put her back together....

IMHO
I did a little searching on the web and found this...

YAMAHA RECALL - #M2003-019 2003 Denso Coils - R6Network.com





I've already been on the phone with the local Yamaha dealer for about 15 minutes trying to convince them to look up the bulletin and do what Yamaha said and replace all 4 direct coils regardless of warranty status.

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post #6 of 7 Old 10-07-2009, 10:14 AM Thread Starter
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The local dealer called back and said they will take care of it free of charge. Not bad considering they suck at customer service in the parts department.

They did say it will take 2 or 3 weeks though. I'll have to keep my mouth shut about how all I need is the parts and an hour and I'll have it fixed.

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post #7 of 7 Old 10-12-2009, 08:12 PM
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Good news that they're covering it. I just saw the thread and immediately thought of the '03 R6 recall on the coils..........I had one too, but mine was lucky to dodge the bullet on the bad ones

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