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F4 Champion Coil Replacement - Plug/play

23K views 25 replies 14 participants last post by  esq'z me 
#1 ·
SOLVED: Plug/play Champion coil replacement

Background:
When MV F4s began using individual stick-style coils, they came from the factory with Champion brand stick coils. Then, after a time, F4s began to be fitted with Beru stick coils, with a different style connector. I have a 2005 750S Brutale with Champion coils. Recently my #4 coil died and I had trouble sourcing a replacement. A common solution on this forum is to change the connector on the loom and fit a Beru coil. I wanted a solution that retained the original connector, and also felt the Beru coils are too expensive, usually priced well over 100 euro (a piece) or more. My solution below is less than half that price and no extra cost to change connectors.

Solution:
Following a lead from a posting on this forum (a member said he used a Fiat Punto coil), I ordered a Valeo Pencil Coil #245117. This type of automotive coil is fairly common and made by other companies, not just Valeo. The one I found was approximately 40 euro.

Fitment:
The Valeo coil's electrical connector is a direct fit to the MV wiring loom connecor. However, two simple modifications must be made to the new coil. (1) The rubber boot and spring on the Valeo coil is too long. Take your dead Champion's boot and spring and swap those onto the new coil. The Champion's rubber boot and spring fit the new coil without modification. (2) the fixed mounting eyelet on the Valeo coil needs to be ovaled-out slightly with a hand drill and a longer bolt needs to be used to mount it to the top of the engine. The half-moon MV hold-down bracket is no longer used.

Although my description above may seem complicated, once you have the new coil in hand you will see this swap takes minutes and is a clean and easy fit.

Source:

There are dozens of Ebay sellers in Europe selling the Valeo Pencil Coil #245117. Valeo isn't the only company that makes such a coil, cross reference for other makers.
 

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#8 · (Edited)
Update: After 3,000 miles the Valeo replacement coil is continuing to work well in cylinder #4. Then, with the vehicle mileage at 24,000, I had my second OEM Champion unit fail on cylinder #2. I have replaced coil #2 using the procedure above, using a crossed-referenced NGK unit (list of cross referenced coils to follow). While I was making the swap I snapped a few photos to add to the description above.

Here are the two coils. The Champion is on top, and the "Fiat" (meaning Fiat-type) coil is below. You can see that the Fiat-style is slightly longer, the additional length as a result of the longer rubber boot.
 

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#11 ·
The new Fiat-style coil has a fixed mounting eyelet. This will work, but the hole is too close to the body of the coil, in order to get the mounting bolt to work, the mounting eye needs to be enlarged. The photo shows where I've inked the area that needs to be modified. Use a rat file or drill to enlarge in this direction
 

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#14 ·
The following list are all the same cross-referenced Fiat-style coils. I have only personally used the Valeo and the NGK, but there is no reason to believe that all these models will work. Some are cheaper than others, some are of higher quality than others. YMMV.

Beru: ZS322,
Blue Print: ADL141401,
Bosch: 0986221043,
Delphi: CE20056-12B1,
Delphi: CE2005612B1,
Fuel Parts: CU1143,
Hans Motors: 925FI0090,
Intermotor: 12741,
Kerr Nelson: IIS037,
Lucas: DMB861,
Magneti Marelli: 060740303010, 403C, 60740303,
Marelli: 060740303010, 403C, 60740303,
Meat & Doria: 10332, 10549,
Mobiletron: CE-72,
NGK: 48061,
Quinton Hazell: XIC8234,
Sovereign: SC046,
Valeo: 245117
 
#15 ·
@exbike: This is excellent information and thank you for the photos!

I have made this thread a STICKY THREAD.
 
#20 ·
You will have to route the wiring to plug into the reversed Fiat coils....I would think it will work, but may take some careful planning to get the wires to reach.

OR...you could cut the Fiat locating tabs off and fabricate some aluminum to create a new hold down. Good luck.
 
#21 · (Edited)
As mentioned above, the Beru ZS378 Ignition Coils are super expensive compared to the ZS 322s.
UPDATED:
The reverse swap (ZS 378->ZS 322 or compatible) can be done, I have replaced all 4 ZS378 with Bosch 0986221043 ignition coils on a 2013 1090RR and the bike seems to be running fine, without any issues.

To fit the coils to my bike I had to make leads that plugged into the existing loom and fitted the new coil, as well as making brackets that utilised the existing bolt hole in the cam cover, and which wrapped around the coils to apply pressure to the lugs ( I used 6mm aluminium flat bar and shaped to suit a cardboard template. The lead requires using the specialist plugs listed below, note you will need the correct type of crimping tool (which I bought from cycle terminal when I purchased the loom plug). This tool was also able to be used to crimp the pins for the coil connector. As I have not changed any of the bikes wiring I can now use either the ZS322 compatible coils and ZS378 if I choose to again in the future, assuming I don't lose the OEM mounting brackets.

BOSCH COIL: I swapped over the coils to the Bosch 0986221043 (as listed in the forum thread below) and only needed to change the rubber grommet at the top of the original coil to provide a good seal against the cam cover. I did not change over the rubber part that fits the spark plug as the Bosch coil is only 3-4mm longer overall. The rubber spark plug connector could be trimmed for length but I found it compressed easily enough without needing any trimming. The Bosch coil has mounting lugs (unlike the original SZ378) and I was not able to reuse the OEM coil holding brackets as mentioned above. I picked up the coils for $60 AUD each.


2013 LOOM CONNECTOR: The plug to use to connect to the 1090 RR loom is the Bosch Kompact 1A. As mentioned here (thanks to this thread.. https://www.mvagusta.net/forum/20-m...ampion-ignition-coil-replaced-beru-zs378.html ). Bosch connector 1928403870 listed on Bosch Kompact 1 is the one. This place in Australia also seems to stock the connector... https://www.automotiveconnectors.com.au/bosch-1928403870-plug-housing-1928403870.html.
Bosch details: https://www.bosch-connectors.com/search?q=1928403870
Drawing of plug: https://gs-gsconnector-us.resource.bosch.com/media/A928000452-DEENW10B00 (21).pdf

BOSCH COIL CONNECTOR: The connector to use with the Bosch 0986221043 ignition coil is :
• Bosch coil compatible connector:C-03FR-P65 (coil Plug)
o https://www.efihardware.com/products/3139/3-pin-bosch-coil-connector
o
 

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#22 ·
Just wanted to share my two cents here. Recently swapped all four stock Champion coils and spark plugs on my 750S for NGK ones. Bike seems to run fine except for one thing. With the new coils I can’t seem to rev her up to the original rev limiter. Revs seem to run out some 800rpm lower than usual. Mine now maxes out around 11.000rpm. Also unable to hit the magic red ‘rev limiter’ light anymore.

I suspect the characteristics of the NGK coils are somewhat different in a way that they just don’t load quick enough to really hit the high rpm’s.

Someone else have a different take on this?
 
#24 ·
Had changed my coils with the ngk ones and I have the same problem with you.
The bike runs fine till 11.000 rpm and then roughens up (like bogging) and stops accelarating at about 12.500rpm
Can't make it rev up to the rev limiter when in gear. In neutral revs all the way up to the rev limiter
Have you come around with a solution?
 
#23 ·
So my understanding is a Valeo Pencil Coil #245117.is a straight replacement for the champion on a 2005 910 S and just change over the boots and springs .
Just got a second hand champion but want to change all 4 down the track ..
SO no downside to this change over except more beer money
 
#25 ·
Hi Evagelos,

I stuck with the NGK’s and didn’t change anything to be honest. Basically accepted it. Mine doesn’t bog or anything, it just stops accelerating and maxes out a little earlier.

The only thing I’m still not sure of, is whether or not it also accelerates a little less quickly, but I think this is just perception. Still managed to keep up with an ‘07 Honda Fireblade from a standing start just recently so..
 
#26 ·
I just tried the NGK 46015 coils in a 2008 Brutale 910S with 5SM ECU and they did not work.. Maybe they work with the older 1.6M ECU as explained in the beginnings of this thread, but my experience is they do not work with the 5SM.
So the substitute to the Beru ZS322 or Bosch 0986221043 seems to be teh way to go. I will try that as soon as I find some.
 
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