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Re-powering Ignition Coils ? 19 May 2017 13:23 #762229

  • kzdcw
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I went ahead an purchased a 5-pin relay and pigtail and proceeded to wire it n per wired george's article. When I got down to Pin 87 to wire the split wire to the 2 coils in the front ( Power wiring the Coils ). George says to secure the wires to the "lug" of the coil opposite the black or green wire ? There is no lug? These are stock coils and the black wires are soldered to the front side of the coil . The only mounting lug ( in fact there are 2, one in front and one in back ) is the one that mounts the coils to the frame. Is the the lug he's talking about ?

When I turn the key on, it automatically blows the 10Amp fuse ?

What am I doing wrong ?
77' KZ1000A

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Last edit: by kzdcw.

Re-powering Ignition Coils ? 19 May 2017 13:26 #762230

  • loudhvx
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He means the primary terminals.
The relay's output should go to the coils where the red/yellow wire attaches.

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Re-powering Ignition Coils ? 19 May 2017 13:32 #762235

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The yellow/red stripe wire on the coils in the front is what appears to be soldered to the front of the coil at what appears to be a pin coming out of the coil ?

Do I solder these 2 wires from the relay to that pin ?
77' KZ1000A

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Re-powering Ignition Coils ? 19 May 2017 18:40 #762245

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Got It ! Was a real pain to get 2 wires soldered to each coil terminal end. Terminal end coming out of coil barely has enough opening for the yellow/red stripe wire. Kind of a botch job but did it. I did burn a little groove in one of the coils when trying to solder.

Is there something you guys use to fill in a opening in the coil plastic made by the soldering iron ?

Anyway, bike fired right up. Put everything back together, was getting late. I'll clean up all the wiring tomorrow before I ride.

Loudhvx, Thanks again for all of your help.
77' KZ1000A

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Re-powering Ignition Coils ? 21 May 2017 18:12 #762424

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The follow day, i inspected all the wiring and tidied it up a little. Used a little Permatex sealant to seal up to scarred coil from the soldering gun.

Key on/engine off, Voltage up to 11.75 Volts at coil where before it was less than 9 Volts. Big Difference !
77' KZ1000A

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Last edit: by kzdcw.

Re-powering Ignition Coils ? 23 May 2017 20:00 #762606

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kzdcw wrote: The follow day, i inspected all the wiring and tidied it up a little. Used a little Permatex sealant to seal up to scarred coil from the soldering gun.

Key on/engine off, Voltage up to 11.75 Volts at coil where before it was less than 9 Volts. Big Difference !

good job.
1979 KZ-750 Twin

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Re-powering Ignition Coils ? 23 May 2017 21:05 #762609

  • kzdcw
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I Appreciate "All" the Help guys. A good learning experience and it starts like it used too !

When I free up some money, it will be time for a total rebuild. Can't wait.
77' KZ1000A

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