Kz1300 Ignition Health Check

2023-03-31 Spark Plug Caps - Ign Coil RewireGot to thinking about the Martek coils. They have 3 terminals. Two on one side, one on the otherside. Is it possible the second terminal is another tap of the winding?

When I installed these coils, ~1980, I remember not fully understanding the instructions.Sure enough the second terminal, the with a '1' scratched by it, is has a resistance of 1 ohm. Perfect! The ballast resistor is 1.7 Ohms. Add 1 Ohm from the coil, 2.7 Ohms total.Just wht the doctor ordered!

Total resistance, ballast resistor + coil. All 3 read the same value.

To think, a mistake I made 40+ years ago, never questioned, causing weak spark all that time.I'm ashamed, but more happy than shameful, to have found this!Things are looking up!

Checking high tension leads. First one pulled looks corroded. Not good.

Assuming a 5k Ohm cap resistor, a reading of 7.2 MegOhms is not good either.

The end caps are not the same length as 'inner' caps. End caps are shorter. This is an 'inner' cap. 
Pix for Mfr and part number.

End cap part number, e.g. cylinder 1 and 6.

Notes

1. Three of the 6 wires showed intial 'open' when measuring with DMM for Ohms. Corrosion where spring contacts wire connection.
2. The spring enters the cap first, followed by resistor, held in place with a 'nut' that has center hole which slides over spark plug end.
3. Caps for cylinders 1, 6 have built-in, non user removable 5k Ohm resistors. All other caps have removable spring, resistor, nut.
4. Re-gapped plugs to .035" from .030.

Happiness was short live however..She won't start now. Cranks, but no fire. Checked for spark, yep, it's got spark. Weak puny spark.

...and I've been having intermittent starter motor problems.. probably, hopefully the control switch? It hits, then, I'm therozing, opens, and the starter quits turning.To be sure, changed the 2011 battery with a known good battery, same symptoms...and the one plug I pulled was bone-dry. Opened a float bowl drain, and fuel came out.By then it's cold, dark, and I'm defeated.

2023-03-31 She Runs Again!

2023-03-31 Broken Coil, Spark Plug Tester, Fix NO SPARK conditionThe big idea to place primary resistance to desired 2.7 ohms failed miserably. Weak, almost non-existant spark.Put coil primary wiring to 'As Found' condition, almost 4 ohms on primary, and spark returned. Glad I didn't damage the Darlington power transistors in the IC Igniter Position '3' is the 1 ohm winding. '1' is the higher resistance winding that works.

Starter motor relay re-work. Kinda loose wire in primary connector, cleaned all connectors, and leads going to starter motor/ground.
In the long run, didn't fix a thing. The starter kicks out after about 5 seconds. Releasing the starter button I can hear the relay kick out..

Split coil. I think it broke when the nut was tightened. Don't recall seeing the break earlier, and I was looking...

Well, I had found a good replacement coil, then the site crashed and we lost 6 weeks and my post. Maybe Kawboy remembers the manufacture I found?

Searching the web, found these... from YellowSquare

It's been decades since I installed the Martek coils... No clue how the stock coils mounted. 
Anyone have a good memory and or pics?

Thanks!

Answered my own question..
 

2023-11-19 Kz1300 New Coils Install
<This site only allows minimal external links, so can't cut and paste thread here> 

The temporary work gig at the nookie plant is over, about 1 week ago. Finding my civilian legs again, time to complete some projects.How about we start with the bike already on the lift?Pics of original install using Martek coils. I did this...1982 or so? New Coils Mocked Up