Dyna coils are high-performance ignition coils used in motorcycle ignition systems to provide consistent and powerful spark for optimal engine performance. This article provides detailed installation instructions and technical guidance based on user experiences and official documentation from verified sources.
For DIY motorcycle enthusiasts and technicians, installing a Dyna coil requires precision, the right tools, and adherence to specific procedures to ensure reliability and safety. The following sections outline the materials required, the step-by-step installation process, and key considerations for troubleshooting and compatibility.
Materials and Tools Required
A successful installation of a Dyna coil begins with gathering the necessary components and tools. The following items are recommended based on the documentation provided:
- Dynatek DC11-2 Ignition Coil: This is the primary component. It must be sourced directly from Dynatek or an authorized vendor to avoid counterfeit products.
- 7mm Hypalon Copper Core Wire: Copper or steel core wire is essential. Avoid using carbon wire, as it may affect performance.
- Taylor 180-Degree Spark Boots (PN: 46052): These are preferred over the standard boots included in the Dyna kit due to their superior quality.
- NGK XD05F Caps: These are now discontinued, but alternatives like the 180-degree Taylor boots or DR8ES-L spark plugs can be used.
- Spark Plug Wire Stripper and Crimp Tool: A high-quality tool is necessary for precise crimping and stripping.
- 6.3mm Parallel Latching Canon Plugs: These are used for secure connections and can be sourced from specialized vendors like Vintage Connections.
- Yellow and Green 18AWG SAE J-1128/Automotive Grade Wire: These are used for specific circuit connections. Only small lengths are needed.
- Crimp Tool for Terminals: A dedicated tool ensures consistent and reliable crimping.
In addition to these components, the following tools are required:
- Heat Gun: Used to soften the spark boot for installation.
- Soldering Iron (35W or solder gun): Required for soldering the wire connections.
- Rubbing Alcohol and Old Toothbrush: Used to clean the terminals after soldering.
- Punch and Drill Kit: Necessary for preparing the crimp terminal.
- File: Used to smooth the edges after drilling.
- Tinning Fluid: Specifically for electronics, to prevent corrosion.
Installation Process
The installation process is methodical and requires attention to detail to ensure the Dyna coil functions properly. Below is a step-by-step guide based on the instructions provided in the source material.
Step 1: Prepare the Wire and Terminal
- Cut the wire to the desired length based on the installation requirements.
- Heat the spark boot with a heat gun to make it easier to slide over the terminal.
- Strip the insulation using a proper wire stripper.
- Twist the exposed wire to prepare it for crimping.
- Use a punch to create a center mark on the crimp terminal. This helps in drilling a hole to pass the wire through.
- Drill the hole in the terminal. A bit of tap/drill fluid may be used to ease the process, although it is not mandatory.
- Clean the edges of the hole using a file. A points file is recommended for this task.
- Apply tinning fluid to both sides of the hole to ensure a good solder joint. It is crucial to use electronics-grade flux to avoid corrosion.
Step 2: Crimping and Soldering
- Crimp the connector. Slightly squeezing the top tabs may be necessary to start the crimping process.
- Examine the crimp to ensure it is secure and properly shaped.
- Heat up the soldering iron to approximately 750°F. A solder gun or a 35W iron is sufficient.
- Apply solder from the top and bottom of the hole to create a solid connection.
- Clean the flux with rubbing alcohol using a toothbrush to prevent corrosion and ensure a clean connection.
Step 3: Final Assembly and Testing
- Heat the boot again with a heat gun and slide it over the terminal.
- Check for continuity between the terminal and the other end of the plug. With the cap removed, the resistance should be 0 ohms.
- With both wires attached, test the resistance between the cap ends. Without the caps installed, the resistance should be approximately 16 kilohms.
Additional Notes
- Do not use plumbers' flux, as it may corrode the connector over time.
- Ensure that all connections are soldered and crimped correctly to maintain reliability.
- If the installation involves a dual-output coil, grounding one output may be necessary to ensure the other lead functions correctly. This is particularly relevant for users planning to upgrade to a dual-plug engine setup with Dyna III ignition systems.
Compatibility and Troubleshooting
When installing a Dyna coil, it is important to ensure compatibility with the motorcycle's existing ignition system and components. The following points address key compatibility considerations and troubleshooting tips:
Compatibility
- Dyna III Ignition Systems: If the motorcycle uses a Dyna III ignition system, the coil should be compatible. However, if the system is being upgraded to a dual-plug setup, the grounding configuration may need to be adjusted.
- Spark Plug Boots and Caps: The use of Taylor 180-degree boots is recommended over the standard boots included in the Dyna kit. These provide better durability and performance.
- Wiring Harness: The wiring harness should be compatible with the 6.3mm parallel latching canon plugs. If the existing harness is not compatible, an adapter may be necessary.
Troubleshooting
- No Spark on One Lead: If one lead shows no spark, it may indicate that the coil is not properly grounded or that the wiring is incorrect. Ensure that the grounding is secure and that the connections are soldered and crimped properly.
- High Resistance Readings: If the resistance reading between the cap ends is significantly higher than 16 kilohms, check for poor solder joints, loose crimps, or damaged wiring.
- Corrosion on Connectors: If corrosion is observed on the connectors, it may be due to the use of incorrect flux. Always use electronics-grade flux to prevent this issue.
Safety Considerations
- Always disconnect the battery before beginning any electrical work on the motorcycle.
- Use insulated tools to avoid short circuits and electrical shocks.
- Work in a well-ventilated area when soldering to prevent inhaling harmful fumes.
- Double-check all connections before reassembling the motorcycle and testing the ignition system.
Conclusion
The installation of a Dyna coil requires a combination of technical knowledge, precision tools, and adherence to proper procedures. By following the outlined steps and using the recommended components, users can ensure a reliable and high-performance ignition system for their motorcycles. Compatibility with existing systems and proper troubleshooting techniques are also essential to address any potential issues.