W800
Noob
Hi Everyone,
I bought a new 2019 Kawasaki W800 Cafe recently.
Even before I did the 600 mile service, it was missing on the right cylinder when cold. Even when hot would sometimes "pop" on that side as well. Got more noticeable after I modded exhaust.
The rubber connectors between air box and TB, and TB and intake were super loose, but tightening them didn't fix problem.
I just lived with it, thinking I would eventually just take to dealer and let them figure it out. Then since I was already modding the bike, I thought it might sort itself out after I did some mods.
So, since I was planning this anyways, I installed piggyback ECU, bypassed air injection to exhaust ports, bypassed and capped O2 sensors, routed crankcase breather out of air box.
Also checked for any leaks in exhaust system and replaced both crush washers.
The only "yellow wire Morse code" error codes were the ones from when I ran bike before the O2 sensor bypass caps.
Problem did not go away. If anything, was getting worse.
So last night at around 11 P.M., I was sitting on my bed and realized what the problem (likely) was.
I went down to backyard and removed the gas tank. Pulled right plug wire.
Right spark plug was at least 3 turns loose!!!! I didn't really count, but I remember thinking that it must have been broken, or I didn't have the socket on properly or something. It just kept spinning and spinning. . .
Because it was a new bike, I didn't even think that a spark plug would be loose.
Still misses a tiny bit when cold, since I didn't want to pull the plug out in the dark (and when I was half-asleep). It's way down "into" the head, and I thought I might have some problems getting it threaded back in.
Will pull this weekend and clean both sets of threads, etc. . .
The reason why it missed only when cold was that aluminium expands more than steel under heat. See: https://www.engineeringtoolbox.com/thermal-expansion-metals-d_859.html
Once the bike warmed up, the aluminum head would "grow" enough to seal around the plug!
The reason there is still a very slight miss is likely that the threads of the plug are now very dirty, and hence it's still not getting a good electrical connection until the head heats up. If I still get slight miss after cleaning things up, then will attempt to diagnose secondary underlying problem (like a small intake leak somewhere).
Anyway, the lessons learned for me are:
1) Don't assume that the most obvious cause is not the cause.
2) If it's not air or fuel, by default it's spark.
3) Don't trust that threaded things stay tight.
I bought a new 2019 Kawasaki W800 Cafe recently.
Even before I did the 600 mile service, it was missing on the right cylinder when cold. Even when hot would sometimes "pop" on that side as well. Got more noticeable after I modded exhaust.
The rubber connectors between air box and TB, and TB and intake were super loose, but tightening them didn't fix problem.
I just lived with it, thinking I would eventually just take to dealer and let them figure it out. Then since I was already modding the bike, I thought it might sort itself out after I did some mods.
So, since I was planning this anyways, I installed piggyback ECU, bypassed air injection to exhaust ports, bypassed and capped O2 sensors, routed crankcase breather out of air box.
Also checked for any leaks in exhaust system and replaced both crush washers.
The only "yellow wire Morse code" error codes were the ones from when I ran bike before the O2 sensor bypass caps.
Problem did not go away. If anything, was getting worse.
So last night at around 11 P.M., I was sitting on my bed and realized what the problem (likely) was.
I went down to backyard and removed the gas tank. Pulled right plug wire.
Right spark plug was at least 3 turns loose!!!! I didn't really count, but I remember thinking that it must have been broken, or I didn't have the socket on properly or something. It just kept spinning and spinning. . .
Because it was a new bike, I didn't even think that a spark plug would be loose.
Still misses a tiny bit when cold, since I didn't want to pull the plug out in the dark (and when I was half-asleep). It's way down "into" the head, and I thought I might have some problems getting it threaded back in.
Will pull this weekend and clean both sets of threads, etc. . .
The reason why it missed only when cold was that aluminium expands more than steel under heat. See: https://www.engineeringtoolbox.com/thermal-expansion-metals-d_859.html
Once the bike warmed up, the aluminum head would "grow" enough to seal around the plug!
The reason there is still a very slight miss is likely that the threads of the plug are now very dirty, and hence it's still not getting a good electrical connection until the head heats up. If I still get slight miss after cleaning things up, then will attempt to diagnose secondary underlying problem (like a small intake leak somewhere).
Anyway, the lessons learned for me are:
1) Don't assume that the most obvious cause is not the cause.
2) If it's not air or fuel, by default it's spark.
3) Don't trust that threaded things stay tight.