Dyna S Ignition Installation Instructions
This document provides installation instructions for a Dyna S electronic ignition system on 1970 and later Harley-Davidson motorcycles. It describes removing the point ignition system, installing the Dyna S ignition assembly and rotor, wiring it to the ignition coil, and setting the timing. It also provides testing procedures and specifications to check the ignition system and troubleshoot any problems.
Introduction
This comprehensive guide will walk you through the installation process of a Dyna S electronic ignition system, designed to enhance the performance and reliability of your Harley-Davidson motorcycle. The Dyna S system is renowned for its advanced technology, delivering precise ignition timing and increased spark energy for a smoother, more powerful ride. This guide provides detailed instructions, covering everything from removing the old ignition system to setting the timing and troubleshooting any issues. Whether you’re a seasoned mechanic or a DIY enthusiast, these instructions will empower you to install and optimize your Dyna S ignition system with confidence.
The Dyna S ignition system is a complete, self-contained electronic unit designed to replace your motorcycle’s original points ignition. Its advanced design features a magnetic rotor, which eliminates the need for mechanical points, resulting in greater precision and durability. The Dyna S also boasts high-energy coils, generating a powerful spark that improves combustion and overall engine performance. By upgrading to a Dyna S ignition system, you can experience a noticeable improvement in your motorcycle’s power, responsiveness, and reliability.
This guide will equip you with the knowledge and tools to install the Dyna S ignition system correctly, ensuring a seamless integration and optimal performance. By following the detailed instructions and adhering to the recommended procedures, you can confidently achieve a successful installation and enjoy the benefits of a modern, high-performance ignition system.
Overview of the Dyna S Ignition System
The Dyna S ignition system is a revolutionary upgrade for Harley-Davidson motorcycles, offering a significant leap in performance and reliability over traditional point-based ignition systems. It stands out as a complete, self-contained electronic unit, designed to seamlessly replace your motorcycle’s existing ignition system. Its advanced features include a magnetic rotor, eliminating the need for mechanical points and ensuring more precise and consistent ignition timing. This, in turn, translates into smoother engine operation, improved fuel efficiency, and a noticeable increase in horsepower.
The Dyna S utilizes high-energy coils, capable of producing a powerful spark that ignites the fuel-air mixture with greater efficiency. This enhanced combustion process translates into better performance across the entire rev range, delivering more power and torque, especially at higher RPMs. The system also boasts a robust design, engineered to withstand the rigors of demanding riding conditions. Its durable construction ensures long-lasting performance and minimal maintenance requirements.
The Dyna S ignition system is designed to be compatible with a wide range of Harley-Davidson models, offering a straightforward upgrade for most Big Twins and Sportsters. It is a popular choice among both casual riders and professional racers, as it provides a significant performance advantage without compromising reliability. Whether you seek enhanced power, improved fuel economy, or simply a smoother running engine, the Dyna S ignition system offers a compelling solution.
Tools and Materials Needed
Before embarking on the Dyna S ignition installation, ensure you have the necessary tools and materials readily available. This will streamline the process and minimize any potential delays or frustration. Here’s a comprehensive list to get you started⁚
- Dyna S Ignition System⁚ This is the core component of the installation, so make sure you have the correct model for your specific motorcycle.
- Torque Wrench⁚ A torque wrench is essential for ensuring proper tightening of bolts and fasteners, preventing over-tightening and potential damage to the engine components;
- Socket Set⁚ You’ll need a variety of sockets to remove and install the various bolts and nuts associated with the ignition system. Ensure your set includes the sizes required for your specific motorcycle model.
- Screwdrivers⁚ A set of screwdrivers, including both Phillips and flathead types, will come in handy for various tasks throughout the installation process.
- Wire Strippers⁚ To connect the wires for the Dyna S ignition system, you’ll need a pair of wire strippers to properly expose the conductors for secure connections.
- Crimping Tool⁚ A crimping tool is essential for securing the wire terminals to the ignition system and ensuring a reliable electrical connection.
- Multimeter⁚ A multimeter is a valuable tool for testing the electrical components of the ignition system, ensuring proper operation and identifying any potential issues.
- Timing Light⁚ A timing light is required for accurately setting the ignition timing for optimal engine performance. Ensure you have a timing light compatible with your motorcycle model.
By gathering these essential tools and materials, you’ll be well-equipped to tackle the Dyna S ignition installation with confidence and ease.
Step-by-Step Installation Guide
The installation of a Dyna S ignition system is a straightforward process, but it requires careful attention to detail and adherence to the instructions. This step-by-step guide will walk you through the installation, ensuring a smooth and successful outcome.
Before you begin, ensure that the motorcycle is parked on a level surface and the engine is cold. Disconnect the battery to prevent any accidental electrical shocks during the installation process.
The first step is to remove the existing ignition system. This will involve removing the points plate, the ignition coil, and any associated wiring. Once the old system is removed, you can begin installing the Dyna S ignition assembly. The installation of the Dyna S ignition assembly is relatively simple, involving attaching the unit to the engine using the provided mounting hardware.
Next, you’ll need to connect the wires. Connect the red wires from the Dyna S to the ignition coil, and connect the black wire to the other end of the coil. Finally, you’ll need to set the timing. This involves adjusting the position of the rotor to ensure that the spark plugs fire at the correct time. Refer to the Dyna S instructions for specific timing details.
Once the timing is set, re-connect the battery and start the engine. Test the ignition system to ensure that it is functioning properly. If everything is working correctly, you can enjoy the benefits of a high-performance Dyna S ignition system.
Removing the Old Ignition System
Before you can install the Dyna S ignition system, you need to remove the existing ignition system. This process involves removing the points plate, the ignition coil, and any associated wiring.
Start by removing the three screws that hold the points plate to the engine. These screws are typically located on the front of the engine, near the camshaft. Once the screws are removed, you can gently lift the points plate off of the engine.
Next, disconnect the black and white wires from the points plate. These wires connect the points plate to the ignition coil. Once the wires are disconnected, you can remove the ignition coil from the engine. The ignition coil is typically located near the points plate, on the front of the engine.
Finally, remove any remaining wiring that is connected to the old ignition system. This may include wires that connect to the ignition switch, the tachometer, or other components. Once all of the wiring is removed, you can discard the old ignition system.
Before you install the new Dyna S ignition system, make sure that the engine is clean and free of debris. This will help to ensure that the new ignition system is properly installed and that it functions correctly.
Installing the Dyna S Ignition Assembly
Once you have removed the old ignition system, you can begin installing the Dyna S ignition assembly. This process involves mounting the ignition assembly to the engine, installing the rotor, and connecting the wires.
Start by mounting the ignition assembly to the engine. The ignition assembly comes with two standoffs that need to be installed. These standoffs are used to space the ignition assembly away from the engine. Locate the holes on the ignition assembly that are designed for the standoffs and install the standoffs into those holes.
Once the standoffs are installed, you can mount the ignition assembly to the engine. Align the ignition assembly with the engine and use the screws that were removed from the old points plate to secure the ignition assembly to the engine. Make sure that the screws are tightened securely.
Next, install the rotor. The rotor is a magnetic component that is used to generate the spark. The rotor is typically installed on the crankshaft. Align the rotor with the crankshaft and install the bolt that holds the rotor in place. Make sure that the bolt is tightened securely.
Finally, connect the wires to the ignition assembly. The ignition assembly will have a number of wires that need to be connected to the ignition coil, the ignition switch, and other components. Consult the wiring diagram that came with the Dyna S ignition system to determine how to connect the wires.
Connecting the Wires
Connecting the wires to the Dyna S ignition assembly is a crucial step in the installation process. It ensures that the electrical signals flow correctly, enabling the ignition system to function properly. This section will guide you through the wire connections.
Start by identifying the wires coming from the Dyna S ignition assembly. There will be several wires, typically color-coded for easy identification. Refer to the wiring diagram that came with your Dyna S kit for the specific wire colors and their corresponding connections.
The most common wires are⁚
- Red wires⁚ These wires are typically connected to the positive terminal of the ignition coil.
- Black wire⁚ This wire is usually connected to the negative terminal of the ignition coil.
- White wire⁚ This wire is often connected to the ignition switch.
Carefully connect the red wires from the Dyna S to the positive terminal of one of the coils. Connect the black wire to the other end of the coil for the front cylinder. Refer to the wiring diagram for the specific coil configuration.
Ensure all wire connections are secure and properly insulated to prevent short circuits. Once all the connections are made, double-check the wiring against the diagram to avoid any errors.
Setting the Timing
Setting the timing correctly is essential for optimal engine performance and smooth operation. The Dyna S ignition system typically uses a magnetic rotor, which allows for precise timing adjustment. This section will guide you through the process of setting the timing.
Before starting, ensure the engine is cold and the ignition is off. Refer to your motorcycle’s service manual for the specific timing specifications for your model. The timing is typically measured in degrees before top dead center (BTDC).
Using a timing light, align the timing mark on the crankshaft with the timing mark on the timing plate. The timing mark on the crankshaft is usually located on the timing cover, while the timing mark on the timing plate is located on the engine case.
Adjust the timing by rotating the Dyna S ignition assembly until the timing mark on the rotor aligns with the timing mark on the timing plate. Secure the ignition assembly in place once the correct timing is achieved.
It’s crucial to double-check the timing after the initial adjustment, as small variations can affect engine performance. Refer to your motorcycle’s service manual for detailed instructions on setting the timing and troubleshooting any issues.
Testing and Troubleshooting
After installing the Dyna S ignition system, it’s essential to test its functionality and troubleshoot any potential issues. This section outlines some common testing procedures and troubleshooting steps to ensure a smooth and reliable ignition system.
One of the first steps is to visually inspect the wiring connections for any loose or damaged wires. Ensure all connections are secure and free from corrosion. You can also use a multimeter to test the continuity of the wires and confirm that there are no breaks in the circuit.
Next, check the ignition coil for proper operation. Apply power to the coil and measure the voltage output using a multimeter. The voltage should be within the specified range for your specific coil. If the coil is not producing the correct voltage, it may need to be replaced.
If you’re experiencing ignition problems, it’s also crucial to inspect the spark plugs. Ensure they are properly gapped and in good condition. Worn-out or improperly gapped spark plugs can hinder ignition and cause misfires.
If the ignition system is still malfunctioning, check the timing again. Incorrect timing can lead to a variety of issues, including poor performance, backfiring, and engine damage. Use a timing light to ensure the timing is set correctly according to your motorcycle’s specifications.
Maintenance and Care
Proper maintenance is crucial to ensure the longevity and optimal performance of your Dyna S ignition system. While the system is designed to be reliable and low-maintenance, regular checks and adjustments can help prevent issues and extend its lifespan.
One important aspect of maintenance is keeping the ignition system clean. Dust, dirt, and moisture can accumulate over time, affecting electrical conductivity and causing problems. Regularly clean the ignition cover and components with a soft brush and compressed air to remove debris.
Periodically inspect the wiring connections for signs of corrosion or damage. If any wires are frayed or loose, replace them immediately to prevent electrical shorts or malfunctions. Additionally, check the spark plugs for wear and tear and replace them as needed.
It’s also advisable to inspect the rotor and pickup assembly for any signs of damage or wear. If the rotor shows signs of cracks or the pickup assembly is misaligned, it’s best to have them replaced by a qualified mechanic.
Finally, remember to follow the manufacturer’s recommendations for routine maintenance intervals and use high-quality parts and fluids for any necessary repairs. By following these guidelines, you can ensure your Dyna S ignition system remains reliable and performs optimally for years to come.