On an FJR there are two coil packs, each firing two plugs. The computer gives a momentary ground to each coil so that each cylinder gets a spark for ignition and the exhaust stroke.
I found the following diagram and verified against the schematic in the manual.
Installing COPs is a good way of eliminating the high voltage wire, which can corrode at the spark plug connection point or which can suffer from insulation breakdown and the short to frame - effectively causing a cylinder to periodically not work.
My ignition system issue became very pronounced after I gave my bike a pressure wash. Nice and clean, sounds like a triple, pulls like a Sportster.
Having done the same procedure on my VMax, for the same reasons, I went on eBay and bought a set of GSXR 1000 COPs for $20. A set is all 4. After some research that I had done previously, the COPs to get are Denso, not Mitsubishi. COPs do not have a particular polarity BUT I keep consistent when making the harness. Looking into the plug, I call the left terminal +.
Also got some new plugs - standard NGK per the manual gapped as required by the manual for the FJR. Note this is important. New plugs are needed since one is fouled for sure and you are this deep into the job already.
Next came the fun part:
Tank gets drained and removed
T Bar comes off
Left and right fairings come off
Now there is room to work:
Step 1 locate the two coils. One is bolted to the front of the frame on the right side of the bike. The second is located just forward of the first - between the frame and the headlight.
Step 2 create a new harness for the COPs. I picked up a set of COPs connectors (they are pretty much universal) and some decent multi strand copper wire from Radio Shack. Measure twice. Should be about 29" from cylinder #1 to the harness connection under the headlight and 25" from cylinder #2 to the harness connection by the frame. (Frame mounted coil feeds cylinders #2&3). The connection to the harness is just a simple blade terminal, so you need 2X of +&- or four blade terminals. Note: unlike the diagram posted above, I elected to run separate positive wires from the OEM harness points. Since the harness is routes in some tight spaces, I added nylon mesh looming over all of the new wiring, shrink wrap seals over all solder joints and small zip ties for strain relief. I didn't take a picture of the FJR harness I made, but here is a pic of the VMax harness. The black connectors are the universal COP connectors that I refer to:
Step 3 clip the old ignition wires by each cylinder connection. Then pull three of the old wires out. This makes some room for the COPs harness to be fed back through the same routing as the original ignition wires. Use electrical tape to attach the COPs harness (blade terminal connection side) to the last remaining ignition wire. Don't be shy about the electrical tape, make the connection smooth. Gently pull the old ignition wire out and fish the new COPs harness thru.
Step 4 replace old plugs and install the COPs sticks. The fit is pretty much perfect with no need to hack the old rubber cylinder caps. Each COP fills the cavity completely and the length of the GSXR 1000 Denso COP just clears the cylinder head cover. Plug in your new harness.
Step 5 install T Bar and fuel tank and start the bike. Nice to know that there was no confusion on the harness routing or cylinder connection order.
Step 6 put everything back together.
Step 7 don't forget to top up the blinker fluid before going on a shakeout ride:
I found this upgrade to be extremely worthwhile.
When I bought the FJR last year and ran some Seafoam through it, I thought it was silky smooth and powerful. Different than my VMax with higher end power, but less low end torque - even when I thought it was running well and smooth.
With the COPs, I found the throttle response to be snappier and the engine torquier ( I know no such word) - especially on first gear launch with low throttle.
Enjoy and ride safe!
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