Replacing coils in my KZ650B2

Working on replacing the coils on my KZ650B2 1978.

This is the first step before installing Dyna ignition.

You should see how nasty my old coils were:

Got the first coil hung, facing downwards and forwards per the docs that came with it. The mounting is improvised, as the old bolts were too short. Used M6-1.00 x 40 bolts, same thread as old ones. Nylon stop nuts and nylon spacers on the bolts.

Since I'm a belt-and-suspenders kind of guy, I crimped AND soldered the primary wires.

Think my mounting is ok?

Here's a concern I have: The yellow/red wire is very close to the head of the mounting bolt. I'm a little worried it might arc to ground there, although that's only 12 volts, so maybe it's not likely. I tried very hard to get a decent photo of it but all the pix I took are pretty bad. What do we think?

You can get some flat stock and drill it to mount it in stock location and another set of holes about a 1/2" away to the side for the wider spacing mounting holes to get further away the terminal.

Or, get some of the clear RTV compound, and overcoat the ignition coil terminal, it will act like an insulator, and prevent vibration from loosening the terminal screws. It will peel off, if needed.

I used about 3 layers of electrical tape on mine ...... not real pretty but hopefully will work.

+1 on the RTV :blink:

Hmm- that's a good idea, modifying the mount with a piece of flat stock. Mebbe I'll try that.
Thanks.

I drilled a new hole in the bracket and used the other mounting hole. I also installed it with the screw head on the outside so that it wasn't as tall.

OLKZ wrote: Here's a concern I have: The yellow/red wire is very close to the head of the mounting bolt. I'm a little worried it might arc to ground there, although that's only 12 volts, so maybe it's not likely. I tried very hard to get a decent photo of it but all the pix I took are pretty bad. What do we think?

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Mine look identical to yours, you don't need to insulate that screw, it's only 12 volts it can't jump a gap.

your still running points at this point? These coils will work but they will be a little hard on the contacts. Not a problem if you go to a electronic ignition soon.

Tyler wrote:

OLKZ wrote: Here's a concern I have: The yellow/red wire is very close to the head of the mounting bolt. I'm a little worried it might arc to ground there, although that's only 12 volts, so maybe it's not likely. I tried very hard to get a decent photo of it but all the pix I took are pretty bad. What do we think?

Mine look identical to yours, you don't need to insulate that screw, it's only 12 volts it can't jump a gap.

your still running points at this point? These coils will work but they will be a little hard on the contacts. Not a problem if you go to a electronic ignition soon.

I haven't fired it up since installing the coils, because the Dyna electronic ignition kit arrived and I'm installing it. But I did change things a little to increase the gap between the bolt head and the primary contact. Read on (next few posts)

The close proximity of the mounting bolt and the screw terminals made me slightly nervous, so I ground the head of the bolt to a small bevel. See photo. The coil is spaced away from the frame with nylon spacers, so I couldn't tighten the nut too much anyhow, so I don't see myself regretting the loss of purchase area for a socket or box wrench.

I also replaced the split washer with a star lockwasher, which is less bulky.

The result is nearly a quarter-inch of gap, which makes me a little more happy.