Upgraded the electrical system on the RZed

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RZed
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Joined: Fri Dec 04, 2009 12:32 am
Location: Oregon City, Oregon

Upgraded the electrical system on the RZed

#1 Post by RZed » Tue Jan 02, 2018 2:25 am

Well, I finally finished up replacing all the electrics on my RZ. Earlier this summer I was on a 2-stroke ride when my bike crapped out half way through. At first it would only idle or run above 4000 rpm, then got to where it would only fire up for a couple of revolutions. Thought it had to be carburation, but it wasn't. I checked out the stator and found one of the readings seemed to be out range from the others. So, I figured I would just replace everything I could being that everything was 30+ years old anyway.

I went ahead and ordered a wiring harness from Economy Cycle. https://www.economycycle.com/shop/yamah ... n-harness/ Also got one of their connector kits too. Plus I ordered up a bunch of extra connectors from Cycle Terminal http://www.cycleterminal.com/

Image

Then I ordered a stator/ rectifier combo along with the Z-PDCI-11 Zeel ignition from Fast From the Past. http://www.fastfromthepast.com/z1010

Image

I was talking to Jim Hindshaw at Fast From the Past to be sure this would all work, and he reassured me in his reply.

Charlie,
Early model cdi systems usually had a stator with 2 separate sets of windings, one to provide power to the cdi box and a larger set of windings to provide power for the battery to provide 12vdc for lights and other electrical equipment.

The PDCI series of ignitions is 100% digital and only needs 12 vdc to function as it does all voltage conversions internally.

This allows us to use the Banshee stator to provide only 12vdc for the battery circuit as it supplies both lights and ignition in this configuration. This is why you must use the PDCI ignition with this setup.

Please note we have reconfigured the Banshee stator to work correctly in this application. If you attempt this with a standard Banshee stator it will damage your electrical system.

Please let me know if you have any other questions.

Jim Hinshaw


So I went about swapping out the wiring harness first by marking all the connectors, then started plugging things into the new harness. Everything matched up as it should. :smt023
I followed the instructions on wiring the stator to the rectifier using the assortment of connectors I had purchased. (On a side note... The stator did not have a wire for the neutral light down by the front sprocket, so I was able to fish an extra wire through with the others and put a terminal on it for the switch.)

It took me awhile to figure out what wire goes where, but slowly I got it. :smt017 I labeled all the connectors to make it easier in the future.

Image

Once I got it all wired back together it fired right up on the second kick!! :smt026

I took it for a test ride and it seemed to run fine until I got up to about 5-6000 rpm. Then it started to misfire. :smt010
Fast forward a couple of weeks. I figured the timing had to be off some. So I ordered a new adjustable timing light since I didn't own one. I finally got some time to check it yesterday and found that the timing mark was about an inch off from where it should be. I tried changing the static angle in the Zeel to compensate, but it didn't seem to move it much.
Then I found in the stator instructions that the wires coming from the coil pickup may need to be reversed. I unplugged the connector, swapped the leads, reconnected it back together and started the bike up. Now the timing mark was right where it should be!! :smt026
I got the bike back out for a chilly test ride and it ran great!! I may play around with the ignition settings later on to squeeze out a little more power, but for now it's fine.

Although I do not like doing electrical work.... overall it wasn't too bad of a job to do. I thought the wiring harness was well worth the money. And the stator/rectifier was reasonable considering the crap shoot you deal with buying used stuff off Ebay.

I figure the bike's good for another 30 years now!! :smt003

Here's a pic of me and the RZ a couple of weeks ago at the Vintage Yamaha Show.
Image

Charlie
1985 RZ 421 Hybrid viewtopic.php?t=9655
99 R1 USD front end
Tarrozi Hi-rise clipons
TrailTech Endurance II Speedo/Odometer
VJ23 swingarm
CBR F4i rear shock/custom dogbones
JL GP stainless pipes
2018 XSR 900

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JonW
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Re: Upgraded the electrical system on the RZed

#2 Post by JonW » Tue Jan 02, 2018 2:40 am

Great write up Charlie, a worthy addition to one of my favourite builds!
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

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RZed
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Location: Oregon City, Oregon

Re: Upgraded the electrical system on the RZed

#3 Post by RZed » Wed Jan 03, 2018 1:42 am

JonW wrote:Great write up Charlie, a worthy addition to one of my favourite builds!
Thanks Jon!!
Hey, BTW I've been meaning to ask if you ever got a chance to get an optimum ignition map dialed in for the Zeel on your 421? I have roughly the same setup as you motor wise. It's hard to find anyone who's got good proven maps to share. :smt017

Thanks,

Charlie
1985 RZ 421 Hybrid viewtopic.php?t=9655
99 R1 USD front end
Tarrozi Hi-rise clipons
TrailTech Endurance II Speedo/Odometer
VJ23 swingarm
CBR F4i rear shock/custom dogbones
JL GP stainless pipes
2018 XSR 900

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JonW
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Location: Sydney
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Re: Upgraded the electrical system on the RZed

#4 Post by JonW » Wed Jan 03, 2018 2:04 am

No sadly I didnt as I stripped the bike totally to swap the frame for an uprated one, its on my lift as my next project to build up but Ive not been in my garage for 5 weeks and wont be on it for a while sorry.
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

p51mustang
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Re: Upgraded the electrical system on the RZed

#5 Post by p51mustang » Sat Oct 26, 2019 9:22 pm

Hi I will be doing this setup here soon may need some help
1984 RZ350
1978 RD 400
1979 Daytona

p51mustang
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Re: Upgraded the electrical system on the RZed

#6 Post by p51mustang » Sat Oct 26, 2019 9:30 pm

Just finished up motor yes Roger at wicked did all the work I am running a VJ22 front end and a VJ21 rear end I was able to get this stuff when I was over seas If you have some time would like to get with you may need some help on a few things
1984 RZ350
1978 RD 400
1979 Daytona

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nokturnal
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Re: Upgraded the electrical system on the RZed

#7 Post by nokturnal » Tue Oct 29, 2019 10:42 pm

love that SRX there...
:smt017

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RZed
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Re: Upgraded the electrical system on the RZed

#8 Post by RZed » Wed Oct 30, 2019 9:33 pm

p51mustang wrote: Sat Oct 26, 2019 9:30 pm Just finished up motor yes Roger at wicked did all the work I am running a VJ22 front end and a VJ21 rear end I was able to get this stuff when I was over seas If you have some time would like to get with you may need some help on a few things
I'll try my best to answer any questions you have.

Charlie
1985 RZ 421 Hybrid viewtopic.php?t=9655
99 R1 USD front end
Tarrozi Hi-rise clipons
TrailTech Endurance II Speedo/Odometer
VJ23 swingarm
CBR F4i rear shock/custom dogbones
JL GP stainless pipes
2018 XSR 900

p51mustang
Posts: 197
Joined: Sun Oct 14, 2012 9:45 pm
Location: Spokane WA
Contact:

Re: Upgraded the electrical system on the RZed

#9 Post by p51mustang » Sat Nov 09, 2019 11:18 pm

Thanks for getting back bud haven't had much time to work on anything here still need a few more parts I am running a VJ22 front end with a Tyga triple clamps would like to mount the fairing to this may have to make up some new mounts
1984 RZ350
1978 RD 400
1979 Daytona

Bikermick7745
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Joined: Sun Aug 25, 2019 8:59 pm

Re: Upgraded the electrical system on the RZed

#10 Post by Bikermick7745 » Tue Jul 18, 2023 3:39 pm

Rzed/Charlie,

I have a 1985 RZ350N and just bought the same wiring harness from Economy Cycle. By any chance do you have any pictures of the harness after fully connected it up? There are some connections that don't seem to match up with components on the bike and wires are different colors. The original harness on the bike had been hacked as the bike was used as Landspeed Racer so this not that much help as a guide. Also there are differences between the RZ350N wiring diagram and the new Economy Cycle Harness.

Any help would be much appreciated.

Cheers,

Mick

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RZed
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Location: Oregon City, Oregon

Re: Upgraded the electrical system on the RZed

#11 Post by RZed » Wed Jul 19, 2023 12:55 am

Bikermick7745 wrote: Tue Jul 18, 2023 3:39 pm Rzed/Charlie,

I have a 1985 RZ350N and just bought the same wiring harness from Economy Cycle. By any chance do you have any pictures of the harness after fully connected it up? There are some connections that don't seem to match up with components on the bike and wires are different colors. The original harness on the bike had been hacked as the bike was used as Landspeed Racer so this not that much help as a guide. Also there are differences between the RZ350N wiring diagram and the new Economy Cycle Harness.

Any help would be much appreciated.

Cheers,

Mick

Mick,
I don't have any pics after I finished. I was able to label the plugs/connectors as I took out the old harness. It was a challenge because as you said some of the coloring on the wires didn't seem to match up.
If I remember correctly, the new harness also had a couple of plugs that weren't needed on my year of bike. Looks like you have a bit of a challenge ahead of you. :smt017

If I get some time to pull the tank and body work I'll snap some pics of the wiring and post them up.

Good luck,

Charlie
1985 RZ 421 Hybrid viewtopic.php?t=9655
99 R1 USD front end
Tarrozi Hi-rise clipons
TrailTech Endurance II Speedo/Odometer
VJ23 swingarm
CBR F4i rear shock/custom dogbones
JL GP stainless pipes
2018 XSR 900

Bikermick7745
Posts: 11
Joined: Sun Aug 25, 2019 8:59 pm

Re: Upgraded the electrical system on the RZed

#12 Post by Bikermick7745 » Fri Jul 21, 2023 12:36 pm

Charlie,

Thanks for the quick reply. Definitely a challenge and I am in awe of folks who can understand and visualize wiring diagrams! Between the various 1985 model wiring diagrams I have looked at I am about 80% there. Got a call into Economy Cycle as well so hopefully they may be able to provide some guidance.

Cheers,

Mick

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