TOPIC:

I did this mod well over 10 years ago.  At one time I thought the relay was going bad, bought a new one, but that was not it.  It probably the dyna coils shorting to the mounting stud.  Later I read here about shrink wrapping the studs to avoid that.  My bike starts with no issues and quickly.  The relay and fuses are under the left side cover.

Yes a lot of guys make the mistake not insulating the round studs. The first time I mounted the Dyna coils I looked and said, O only a few thousand clearance that ain't going to work. I now use nylon spacers.

To build on WOOKIE58's OP, a common voltage drop culprit is often the ignition switch itself.  If voltage at the coil primary isn't at or very close to battery voltage, a bypass relay mod is well worth it.

The link below is a deep dive through the cobwebs & into the rabbit hole that is an OEM Z1 ignition switch.  Although we were chasing an intermittent issue, the cause of voltage drop across the ignition switch also became clear once we saw its innards.

kzrider.com/forum/4-electrical/606810-z-...-and-troubleshooting

Good Ridin'
slmjim & Z1BEBE

Excellent read! Thank you for that link.

Bypass switch installed. I thought I’d post a pic so others could see one installed. Painstaking but I’m a firm believer now that this mod is a good thing to do.