The Dyna S Ignition System is a high-performance electronic ignition system specifically designed for Harley-Davidson motorcycles․ It replaces the traditional points system, offering enhanced performance, efficiency, and reliability with its advanced magnetic rotor technology․

1․1 Overview of the Dyna S Ignition System

The Dyna S Ignition System is a self-contained electronic ignition designed for Harley-Davidson motorcycles, replacing traditional points systems․ It features a magnetic rotor and advanced technology for improved performance․ The system is engineered to mount in the original ignition position, maintaining stock appearance while enhancing reliability․ Compatible with stock or high-resistance coils, it eliminates maintenance associated with points-based ignitions․ Its design ensures a direct replacement, simplifying installation while providing a modern, efficient alternative to older systems․

1;2 Benefits of the Dyna S Ignition System

The Dyna S Ignition System offers numerous benefits, including improved performance, reliability, and ease of use․ It eliminates the maintenance required by traditional points systems, providing a more durable and efficient solution․ The system enhances ignition timing accuracy, leading to smoother engine operation and increased power․ Its self-contained design simplifies installation and ensures compatibility with stock or high-resistance coils․ Riders benefit from reduced mechanical wear and consistent ignition performance, making it a superior choice for Harley-Davidson enthusiasts seeking a modern, high-performance ignition solution․

1․3 Compatibility with Harley-Davidson Motorcycles

The Dyna S Ignition System is specifically engineered for compatibility with Harley-Davidson motorcycles, offering a seamless fit for various models, including Shovelhead engines․ It works with stock ignition coils or those with a primary resistance of at least three ohms․ The system is designed to integrate with the bike’s original timing marks and advance curves, ensuring optimal performance․ Compatibility is further enhanced by its ability to maintain the factory ignition timing characteristics, making it a versatile and reliable upgrade for Harley-Davidson enthusiasts․

Pre-Installation Requirements

Ensure you have a 10mm wrench, Allen keys, and proper safety gear․ Disconnect the battery and prepare the motorcycle on a center stand for easy access․

2․1 Tools and Materials Needed

To install the Dyna S Ignition System, you will need specific tools and materials․ Start with a 10mm wrench for removing the points cover and standoffs․ Allen keys are essential for adjusting and securing components․ Additionally, gather a torque wrench for proper tightening and a multimeter to verify wiring connections․ Ensure you have new gaskets or spacers if required․ Safety gear, such as gloves and goggles, is crucial․ Finally, a clean work area and a service manual for reference will aid in a smooth installation process․

2․2 Safety Precautions

Before starting the installation, ensure the motorcycle is on a stable stand and the engine is cool․ Disconnect the negative battery terminal to prevent accidental ignition․ Wear protective gloves and eyewear to avoid injury from sparks or debris․ Avoid working near open flames or sparks, as flammable vapors may ignite․ Always follow proper grounding procedures to prevent static discharge; Consult the factory service manual for model-specific safety guidelines to ensure a safe and successful installation process․

2․3 Consulting the Factory Service Manual

Consulting the factory service manual is crucial for a successful installation․ It provides model-specific instructions, ensuring compatibility and correct procedures․ The manual details wiring diagrams, ignition timing specifications, and torque values․ Refer to it for locating components like ignition coils and orange/white wires․ It also outlines safety precautions and troubleshooting steps․ Always verify the manual’s guidelines for your motorcycle’s year and model to avoid errors and ensure optimal performance of the Dyna S Ignition System․

Installation Procedure

The installation involves removing the points cover, disconnecting the ignition coil wire, and installing the new ignition assembly․ Tighten securely, then connect the necessary wires, following the provided instructions for your specific model․ Ensure all connections are secure and properly routed to avoid interference․ Refer to the manual for precise torque specifications and wiring diagrams to complete the process successfully․

3․1 Removing the Points Cover

To begin the installation, start by removing the points cover․ This step grants access to the ignition components․ Use an Allen wrench to remove the screws securing the cover․ Gently pull the cover away from the engine, taking care not to damage any surrounding components․ Once removed, set the cover aside in a safe place to avoid loss․ This step is crucial for accessing the ignition system and preparing it for the new Dyna S Ignition System installation․ Ensure the area is clean before proceeding․

3․2 Disconnecting the Points and Ignition Coil Wire

Next, disconnect the wire connected to the points and the ignition coil․ Use a wrench or pliers to carefully remove the wire from the points terminal․ Gently pull the wire away from the ignition coil, ensuring it is completely detached․ This step is essential to prevent any electrical interference during the installation process․ Once disconnected, set the wire aside to avoid accidental reconnection․ Always refer to the factory service manual for specific wire identification and handling procedures․

3․3 Installing the Ignition Assembly

Mount the Dyna S Ignition Assembly in the original points plate position․ Align the assembly with the engine’s surface, ensuring it fits securely․ Use the provided mounting hardware to fasten it in place․ Tighten the screws evenly to avoid warping the plate․ Make sure the assembly is snug but not over-tightened․ The Dyna S system is self-contained, so no additional adjustments are needed during installation․ Refer to the factory service manual for torque specifications if required․

3․4 Tightening the Ignition Assembly

Once the Dyna S Ignition Assembly is properly mounted, secure it using the screws previously removed․ Tighten the screws evenly in a star pattern to ensure the plate sits flush against the engine․ Avoid over-tightening, as this could damage the assembly or engine surface․ Refer to the factory service manual for specific torque specifications․ Ensure the assembly is snug and evenly seated before proceeding to the next step in the installation process․

3;5 Connecting the Blue Wire (for KZ650 Models)

For KZ650 models, locate the spade terminal end of the blue wire provided in the Dyna S Ignition kit․ Connect this spade terminal to the designated connection point on the motorcycle’s wiring harness or ignition system, ensuring a secure and proper fit․ This connection is essential for the ignition system to function correctly, providing the necessary electrical signal for high-performance operation․ Double-check the connection to avoid any loose contacts, which could lead to ignition issues․

Wiring Diagram and Connections

Refer to the wiring diagram for connections․ Locate the ignition coils and identify the orange/white wires, ensuring proper connections to the switched 12-volt wire for optimal functionality․

4․1 Locating the Ignition Coils

Ignition coils are typically located on the rear cylinder and connected via orange/white wires․ These wires link to a common junction in the wire harness, ensuring proper ignition timing․ Refer to the factory service manual for specific locations on your model․ Always verify the primary resistance of the coils to ensure compatibility with the Dyna S system, which requires at least three ohms for optimal performance․ Proper identification and connection are critical for reliable operation․

4․2 Identifying the Orange/White Wires

The orange/white wires are connected to the ignition coils and carry the switched 12-volt power․ Trace these wires from the coils to their junction in the wire harness․ Ensure these wires are correctly identified to avoid misconnection․ They are essential for proper ignition timing and must be securely connected to the Dyna S system․ Verify their function using the factory service manual or multimeter to confirm they are switched 12-volt wires, ensuring reliable operation of the ignition system․

4․3 Connecting the Switched 12-Volt Wire

Locate the switched 12-volt wire, typically connected to the ignition switch or circuit breaker․ Connect one end of this wire to the appropriate terminal on the Dyna S ignition module․ Ensure the connection is secure and properly insulated․ This wire provides power to the ignition system only when the ignition is in the “on” position․ Double-check the connection to avoid electrical issues․ Refer to the wiring diagram or factory manual for confirmation of the correct terminal․ Verify the connection with a multimeter to ensure proper operation․

Timing Mark Adjustment

Access the timing mark by removing the timing mark hole cap․ Use the generator bolt to rotate the engine and set the correct ignition timing․ Adjust the ignition plate as needed, advancing or retarding the timing․ Replace the cap and test the ignition system to ensure proper function and timing accuracy․ Tighten all bolts securely to prevent loosening during operation․

5․1 Removing the Timing Mark Hole Cap

Start by locating the timing mark hole cap, typically found on the engine case․ Use a screwdriver to carefully remove the cap, ensuring not to damage the surrounding area․ Once removed, you will have access to the timing marks․ Before proceeding, make sure the ignition is turned off and the motorcycle is securely supported․ This step is crucial for accurately adjusting the ignition timing․ Refer to your factory service manual for specific instructions and safety precautions․

5․2 Rotating the Engine

To rotate the engine, use the 12 mm generator bolt located on the engine case․ Turn the bolt clockwise to move the engine in the forward direction․ Ensure the ignition switch is in the “OFF” position and the motorcycle is securely supported․ Rotate the engine slowly and carefully to avoid damage․ This step is essential for aligning the piston at Top Dead Center (TDC), which is critical for setting the correct ignition timing․ Always refer to the factory service manual for specific guidance․

5․3 Setting the Correct Ignition Timing

After rotating the engine, align the piston at Top Dead Center (TDC) using the timing mark hole․ Ensure the ignition timing mark on the rotor aligns with the corresponding mark on the ignition plate․ The Dyna S system uses a factory advance curve, so the timing is preset, but proper alignment is still required․ Refer to the factory service manual for specific timing specifications․ Double-check the alignment to ensure accurate ignition timing, as incorrect settings can affect engine performance and efficiency․

Testing and Inspection

After installation, test the ignition system for proper spark and timing accuracy․ Ensure all wire connections are secure and verify the ignition timing aligns with specifications․

6․1 Ignition System Testing

After installation, test the ignition system to ensure proper function․ Use a spark tester to verify spark presence at the spark plugs․ Check the ignition timing by rotating the engine and aligning the timing marks․ Ensure the magnetic rotor spins freely and the ignition module is secure․ Test the system under various engine speeds to confirm consistent spark and timing accuracy․ Consult the factory service manual for specific testing procedures and recommendations․ Proper testing ensures reliable performance and prevents potential issues․ Always ensure all connections are tight and secure․

6․2 Checking for Proper Spark

To ensure the ignition system is functioning correctly, use a spark tester to verify spark presence at the spark plugs․ Attach the tester to the spark plug wire and crank the engine to observe a bright blue spark․ If no spark is detected, check all connections, including the ignition coil and module․ Proper spark indicates the system is operational․ This step is crucial for confirming the ignition system’s functionality and identifying potential issues early․ Always ensure the tester is used correctly to avoid misleading results․

6․3 Verifying Timing Accuracy

After installation, ensure the ignition timing is accurate for optimal performance․ Remove the timing mark hole cap and rotate the engine forward using the 12mm generator bolt․ Use a timing light to check the ignition timing against the factory specifications outlined in your Harley-Davidson service manual․ Adjust the ignition plate as needed to align the timing mark correctly․ Proper timing ensures efficient combustion and prevents engine damage․ Always refer to the manual for precise instructions tailored to your specific motorcycle model․

Troubleshooting Common Issues

Troubleshooting the Dyna S Ignition System involves diagnosing issues like no spark, incorrect timing, or wiring faults․ Consult the factory manual for precise error identification and resolution steps․

7․1 No Spark Condition

A no-spark condition in the Dyna S Ignition System can occur due to disconnected wires, a faulty ignition module, or improper installation․ Check all wiring connections, ensuring the blue wire (for KZ650 models) is securely attached․ Verify the ignition coil’s primary resistance matches the specified range․ If issues persist, inspect the ignition module and rotor for damage․ Consult the factory service manual for detailed diagnostic steps to resolve the issue efficiently․ Proper installation and wiring are critical for optimal performance․

7․2 Incorrect Timing Symptoms

Incorrect ignition timing can lead to poor engine performance, including misfires, reduced power, and backfiring․ Symptoms may also include rough idling or difficulty starting the engine․ Verify the timing mark alignment by referring to the factory service manual for your specific model․ Ensure the ignition plate is adjusted correctly, as improper timing can damage the engine or ignition components․ Use the 12mm generator bolt to rotate the engine and set the timing accurately․ Precise adjustment is crucial for optimal performance and reliability․ Always follow the manufacturer’s guidelines for timing specifications․

7․3 Wiring Connection Problems

Wiring connection issues can prevent the Dyna S Ignition System from functioning properly․ Common problems include loose connections, incorrect wire identification, or damaged wires․ Ensure the orange/white wires are correctly connected to the ignition coils and the switched 12-volt wire is properly linked․ For KZ650 models, verify the blue wire is securely attached to the spade terminal․ Improper connections can result in no spark or inconsistent ignition․ Always refer to the wiring diagram and double-check connections before testing the system to avoid further complications and ensure reliable performance․

Maintenance and Upkeep

Regular maintenance ensures the Dyna S Ignition System performs optimally․ Clean the ignition assembly, inspect the rotor and ignition coil for wear, and replace damaged components promptly․

• Clean the ignition system to prevent dirt buildup․
• Inspect the rotor and coil for wear or damage․
• Replace worn or damaged components to maintain performance․

8․1 Cleaning the Ignition System

Cleaning the Dyna S Ignition System is essential for maintaining its performance and reliability․ Start by removing the ignition cover to access internal components like the rotor and ignition coil․ Use a soft brush or clean cloth to gently remove dirt and debris․ Avoid using harsh chemicals or abrasive materials to prevent damage․ Compressed air can be used to blow out loose particles․ After cleaning, reassemble the components securely, ensuring all connections are tight and protected from moisture․ Regular cleaning prevents dirt buildup that could interfere with the magnetic rotor’s function and spark timing․ For optimal results, follow the manufacturer’s recommendations and consider environmental factors, such as frequent riding in dusty conditions, which may require more frequent maintenance․ Always handle electrical components with care to avoid static discharge and ensure the ignition is turned off during the process․ By systematically and meticulously cleaning the ignition system, you can ensure the motorcycle runs smoothly and efficiently, maintaining the Dyna S Ignition System’s advanced features and reliability․

8․2 Inspecting the Rotor and Ignition Coil

Inspecting the rotor and ignition coil is crucial for ensuring optimal performance․ Visually examine the rotor for wear, cracks, or excessive carbon buildup․ Check the ignition coil for signs of damage, corrosion, or loose connections․ Use a multimeter to test the coil’s primary and secondary resistance, ensuring it matches the manufacturer’s specifications․ If any damage or wear is detected, replace the components immediately․ Avoid using abrasive cleaners, as they may damage the coil’s surface․ Regular inspection helps prevent ignition failures and ensures consistent spark production․ Always refer to the factory service manual for specific guidance on testing and replacing these components․ By maintaining the rotor and ignition coil, you can ensure reliable ignition system operation and prevent potential issues during rides․ Regular inspections are a key part of maintaining the Dyna S Ignition System’s high performance and reliability․

8․3 Replacing Worn or Damaged Components

Replacing worn or damaged components is essential for maintaining the Dyna S Ignition System’s performance․ Start by disconnecting the battery to ensure safety․ Remove the worn or damaged part, such as the rotor, ignition coil, or wiring, and install the new component․ Tighten all connections according to the factory service manual specifications․ Reconnect the battery and test the ignition system to ensure proper function․ Regular replacement of worn components prevents ignition failures and ensures reliable engine operation․ Always use genuine or high-quality replacement parts to maintain system integrity and performance․ Timely replacements are critical for avoiding costly repairs and ensuring your motorcycle runs smoothly․

Advanced Features of the Dyna S Ignition

The Dyna S Ignition features advanced magnetic rotor technology, factory advance curve utilization, and a high-performance ignition module, ensuring enhanced reliability and superior engine performance․

9․1 Magnetic Rotor Technology

The Dyna S Ignition System features a magnetic rotor designed to eliminate traditional points, enhancing reliability and performance․ This advanced component provides precise timing accuracy and reduces maintenance needs․ By utilizing the factory advance curve, the magnetic rotor ensures optimal spark delivery at all engine speeds․ It is fully compatible with stock components and integrates seamlessly with Harley-Davidson engines, offering a high-performance ignition solution without compromising original specifications․ This technology contributes significantly to the system’s overall efficiency and durability․

9․2 Factory Advance Curve Utilization

The Dyna S Ignition System incorporates the factory advance curve, ensuring precise spark timing aligned with the engine’s original specifications․ This feature eliminates the need for manual timing adjustments, providing optimal performance across all RPM ranges․ By utilizing the factory advance curve, the system maintains the engine’s intended characteristics, delivering consistent power and smooth operation․ This integration enhances reliability and simplifies installation, as no additional timing adjustments are required beyond the initial setup․

9․3 High-Performance Ignition Module

The Dyna S Ignition System features a state-of-the-art, high-performance ignition module designed to deliver consistent and precise spark energy․ This module is engineered to handle high RPM and high-load conditions, ensuring optimal ignition performance․ Its advanced design provides reliable operation under various riding conditions, enhancing overall engine efficiency and power delivery․ The module’s high-quality construction and precise spark control reduce wear on ignition components, offering long-term durability and consistent performance for Harley-Davidson motorcycles․

The Dyna S Ignition System enhances performance, reliability, and installation ease for Harley-Davidson motorcycles, making it a top choice for enthusiasts seeking efficiency and a reliable upgrade․

10․1 Summary of Key Installation Steps

The Dyna S Ignition System replaces the traditional points system, offering a performance upgrade․ Key steps include removing the points cover, disconnecting the ignition coil wire, and installing the new assembly․ Secure the unit with previously removed screws and connect the blue wire for KZ650 models․ Refer to the factory service manual for specific timing marks and ensure proper wire connections․ Double-check all connections and timing accuracy before starting the engine for optimal performance․

10․2 Final Checks Before Operation

Before starting the engine, ensure all connections are secure and the ignition assembly is properly tightened․ Verify the timing mark alignment and check for any loose wires or components․ Inspect the rotor and ignition coil for damage or wear․ Test the spark at the spark plugs to confirm proper ignition function․ Review the installation steps to ensure no components were missed․ A final inspection ensures reliability and optimal performance of the Dyna S Ignition System․