I have been trying to find why my Zuki will not start. I went by the factory manual, one step at a time. It shows a Code 12, and my ECM was re-firbished three years ago.

Inatially, yellow spark at the plugs, and only jump about 1/4-inch. Then no spark. Testing with the manual, one component at a time, said the Igniter and Coil were OK.   

A friend brought his Zuki over. We put my Igniter and Coil on his Zuki. It would not start.  We used his Igniter and my Coil, no start. Used my Igniter and his Coil and it started right up.

Looking closer at the Coil, we discovered cracks in the potting material.

I ordered a new Coil, and next week, hope to have my Zuki fired up.

Can anyone explain how checking the Coil by the factory manual can show it as OK, but it will not work on a running Zuki when it is installed on it?


For what ever it is worth, it appears the Coil is unique to '90 thru '95 Samuri's. There are about five manufactures (google), with the price from $60 to $180. Factory is $180.    A Wreaking yard (on Internet) wanted $90 for a used one. 


Wayne

Yes, 90-95 samurai coils are unique (those are the EFI years, where earlier models are carbed and therefore use a different coil).

I can't explain the "tested good but is faulty" deal......just one of those things I guess.  Just be glad you had another that you could swap in to figure it out.....otherwise you might not have ever figured it out, without spending a lot of time and money swapping various parts.

That is my concern, having another vehicle to swap parts with. Another vehicle is not always available. It shakes your confidence in the factory manual, if it says a part is good, when it is not.


Wayne