Wired George Mod HELPPPPPPPPPPPP

[sprint]

I have had a lot of problems with my A4 since it was rebuilt in April this year with it 'farting' about on tick over and generally being a pain when coming off low or closed throttle.

Black sooty pugs etc. However, after months of stripping the carbs apart, cleaning, checking the float levels endlessly, changing plugs I chanced upon the fact that the main 20A fuse had a high resistance on one side of the contacts which meant that I only had 8.5V at the coils. Cleaned the fuse contact and problem solved. However, the volts were still a bit low, 10.3V with engine not running and 10.8V running at tickover and around 11.3V with the engine reved.

So I decided to undertake the Wired George Mod, which I have now done. I have a Dyna electronic ignition kit fitted on which I had the Red power lead also connected to the same coil feed. Following the mod I now get the full battery volts directly to the coil and Dyna without the engine running.

However, I do now have a concern? Without the mod whilst the coil/Dyna voltages were a bit low a low revs the bike ran OK. With the mod the power to both are now via an electro mechanical device in the form of the relay and it's contacts whereas before the coils and Dyna were directly wired. Has anybody who has undertaken this mod ever had any problems with the relay failing or with the relay contacts?

[Pigford]

Just carry a spare relay if you're worried..... there was also a thing about a diode to reduce "relay voltage spike" - but not 100% necessary

[wilsonsjw11]

Just carry a spare relay if you're worried..... there was also a thing about a diode to reduce "relay voltage spike" - but not 100% necessary

Relays are available from Ebay etc complete with a FLYBACK diode to give protection to the relay, they are not expensive but take care when connecting the coil wires as they are polarity conscious and the diode will be destroyed if connected arse backwards.
For more info Google flyback diode.
Regards
Steve

[sprint]

Thanks for the replies. Do intend to carry a spare relay.

Also I made up a separate loom with st 3.9 mm connectors between the relay wires so that I can just join up the two wires that feed the power to the coils, Y/R, and totally by-pass the relay if necessary.

Will look into a relay with a Flyback diode, but just wanted to get some feedback as to how reliable the mod is.

[Pigford]

Thanks for the replies. Do intend to carry a spare relay.

Also I made up a separate loom with st 3.9 mm connectors between the relay wires so that I can just join up the two wires that feed the power to the coils, Y/R, and totally by-pass the relay if necessary.

Will look into a relay with a Flyback diode, but just wanted to get some feedback as to how reliable the mod is.

Answer is - just as reliable as the rest of the Zed electrics (if a half decent relay is used)

[sprint]

Thanks for the replies. Do intend to carry a spare relay.

Also I made up a separate loom with st 3.9 mm connectors between the relay wires so that I can just join up the two wires that feed the power to the coils, Y/R, and totally by-pass the relay if necessary.

Will look into a relay with a Flyback diode, but just wanted to get some feedback as to how reliable the mod is.

Made up relay loom and subsequent fitting.

[wilsonsjw11]

Sprint,
That's a tidy location for the relay and easily accessible.
Regards
Steve

[z1bman]

just needs the main harness routing behind the frame tube instead of on the outside

[sprint]

just needs the main harness routing behind the frame tube instead of on the outside

I looked to do that when I re-assembled the bike, but found that it was not possible to fit the airbox in that position?

Looked at some pictures in the Z900/1000 workshop manuals I have and they all showed the harness on the outside as I have done mine?

[z1bman]

this is how it should be routed wayne1960 did the same mistake as you have done but he has now put it where it should be & he has a standard bike

[sprint]

Sprint,
That's a tidy location for the relay and easily accessible.
Regards
Steve

Thanks.

It is a good/easy place as long as you do not have the original rectifier, as in my case.

I replaced the original separate rectifier and regulator with a Wassell combined unit onto which I grafted a std Green plug kindly donated by Hobbo.

[Kev1R]

Still considering doing this mod
Just when you think you understand it, another grey area raises it's head!

Apart from the diode thing & best way to avoid blowing lights !!! -

I am sure the answer to this one is more straightforward -
What is 12ga wire & 18 ga wire in english?

[PAULJAC47]

http://www.powerstream.com/Wire_Size.htm

[needaz1100r]

http://www.powerstream.com/Wire_Size.htm

This gives you AWG to mm2

http://www.rapidtables.com/calc/wire/awg-to-mm.htm