Ignition problem's

[warren3200gt]

Just to play devil's avacado.
Wired George mod supplies battery voltage to the coils when the ignition and kill switch is on.
Brand new Kawasaki wiring loom and switch gear, i.e. when they were new, did exactly the same.
It's only old age and poor connections in an old loom that stops that from happening.

I don't recall burning out coils every 5 mins back in the day if you switched off when not running as you should.

Which means if your burning out coils with the wired George mod by doing whatever your doing you would have done so on a new bike with a standard loom.
(previso, your charging system is working correctly and your regulator is errr..... Regulating.)

[moizeau]

Was about to say that. I'm guessing the old wiring and voltage drop off hides the charging system failures, The WG mod highlights them.

[Mr Bump]

...faulty relay in the wired george mod so the ignition is staying on whenit shouldn't??? But then the engine wouldn't switch off on the key so maybe not.

Otherwise, as the man says, unless its overcharging the wired george mod shouldn't make any difference, no different to bypassing all the loom and hooking the ignition straight to the battery, the ignition components will still only get slightly less than charging voltage (14.4v or a bit less) at the absolute maximum . Maybe Dynas just aren't quite up to taking 14 odd volts.

Possibly an intermittent bad earth to the regulator causing intermittent overcharging that's frying the dyna???

Would that bike have originally had a separate regulator and rectifier, and if so does it still have it? Aged contact point type regulators are the devils work in my limited experience.

Hope that's helpful somehow on some level....

Olly

[warren3200gt]

For a relay to fail in the closed circuit position you would need to put far more current through it to weld the contacts together. Far, far more than the charging system could produce. That's why when they fail they fail in the open circuit position. Which would mean you couldn't get any power to the coils.