The Dyna S ignition system is a high-performance digital ignition upgrade designed for a wide range of Harley-Davidson motorcycles from 1970 to 2003. This system is engineered to enhance the bike's power output, maintain the factory advance curve, and provide greater control over ignition timing. It is particularly suited for models equipped with carburetors and dual-fire ignition systems. The installation process is relatively straightforward, and the system is designed to integrate with the existing wiring and components in most cases.
This article provides a detailed, step-by-step guide based on manufacturer documentation, installation instructions, and technical specifications from the provided source material. It is intended for U.S. consumers, DIY enthusiasts, and technicians seeking to upgrade their Harley-Davidson’s ignition system for improved performance and reliability.
Key Features of the Dyna S Ignition System
The Dyna S ignition system is marketed as a high-performance upgrade for Harley-Davidson motorcycles. According to the provided documentation, the system offers the following key features:
- High-Voltage Spark Output: The ignition system produces spark voltages in excess of 30,000 volts, ensuring a strong and consistent spark under a wide range of operating conditions.
- Maintains Factory Advance Curve: The system uses a magnetic rotor and the original spark advancer to preserve the factory advance curve, which is critical for maintaining the bike’s original timing characteristics.
- Dual-Fire Mode: The system includes a switch to toggle between single- or dual-fire modes, allowing users to adjust the ignition pattern based on their engine setup and performance goals.
- Preprogrammed Ignition Curves: The Dyna 2000-HD1 variant (mentioned in the source) includes four preprogrammed ignition curves for use with stock or modified bikes, including race setups.
- Rev Limiter Function: The system also features a built-in rev limiter, which helps prevent engine damage from over-revving.
- LED Diagnostic Tool: The module includes an LED for troubleshooting and static timing assistance, which aids in the installation and tuning process.
- Compatibility: The system is compatible with a broad range of Harley-Davidson models, including Softail, Dyna, Tour Glide, and Sportster models from the 1970s through 2003.
Installation Overview
The Dyna S ignition system is designed for ease of installation. Most of the process involves removing the stock ignition cover and replacing it with the new ignition module. However, certain steps require careful attention to avoid damaging the timing components or electronic sensors.
Tools and Materials Required
Before beginning the installation, ensure you have the following tools and materials:
- Socket set and wrenches
- Screwdrivers (flathead and Phillips)
- Drill and bit (for removing rivets)
- Pliers or a punch (for removing rivet heads)
- Timing light (optional, for final verification)
- Safety gloves and eye protection
The installation procedure should be performed in a clean and well-lit workspace. It is also recommended to disconnect the battery to prevent accidental short circuits during the process.
Step-by-Step Installation Guide
Step 1: Prepare the Bike for Installation
- Remove the Spark Plugs: This is essential to prevent damage to the ignition system or engine components during the installation.
- Shift into Gear: Place the transmission into a forward gear to lock the crankshaft in place. This ensures that the engine cannot rotate accidentally during the installation.
- Locate the TDC Mark: With the spark plugs removed, rotate the rear wheel to bring the crankshaft to Top Dead Center (TDC) on the compression stroke of the front cylinder. The TDC mark should be visible in the inspection hole.
Step 2: Remove the Ignition Cover
- Remove the Timing Cover Inspection Plug: This allows access to the timing components.
- Remove the Stock Rivets: If the timing cover has not been removed before, the stock rivets must be drilled out. Use a small drill bit to remove only the rivet head. Be cautious not to drill too deeply, as the electronic ignition pickup is located behind the cover and can be damaged if the bit enters this area.
- Install a Replacement Timing Cover: After removing the rivets, install a plain-chrome timing cover from a manufacturer like Custom Chrome (part No. 15-151, as referenced in the source).
Step 3: Install the Dyna S Ignition Module
- Position the Module Baseplate: Rotate the baseplate of the ignition module until the LED on the module turns off and then back on. The baseplate should be tightened at the point where the LED just turns off as you rotate it clockwise.
- Mount the Ignition Module and Cover: Secure the ignition module in place and reinstall the timing cover. Ensure all fasteners are tightened to the manufacturer’s specifications.
Step 4: Connect the Wiring Harness
- Plug in the Wiring Harness: The Dyna S module includes a seven-plug wiring harness that connects to the motorcycle’s existing wiring system. Ensure all connections are secure and properly seated.
- Verify Connections: Double-check all wiring connections to ensure there are no loose or damaged wires. The wiring harness is designed to plug into most late-model Harley-Davidson wiring harnesses.
Step 5: Adjust the Ignition Curves and Mode
- Select the Ignition Curve: The ignition curve and rev-limiter level can be selected by positioning the switches on the rear of the ignition module. The curves are designed to work with a wide range of engine setups, from stock to race bikes.
- Switch Between Single- and Dual-Fire Modes: Depending on the engine configuration, users can toggle the switch to select between single- or dual-fire modes. This allows for fine-tuning of the ignition pattern to match the engine’s requirements.
Step 6: Final Checks and Testing
- Reconnect the Spark Plugs: Once the installation is complete, reconnect the spark plugs and ensure they are tightened to the manufacturer’s torque specifications.
- Verify the LED Function: The LED on the ignition module should be used for troubleshooting and static timing. During operation, the LED can help identify any issues with the ignition timing.
- Test the System: Start the motorcycle and verify that the engine runs smoothly. If the LED remains on or behaves abnormally, refer to the troubleshooting section in the manufacturer’s documentation.
Troubleshooting and Common Issues
The documentation mentions that the LED on the ignition module serves as a diagnostic tool. If the LED remains on during operation, it may indicate a problem with the ignition timing or a faulty connection. The following steps can help resolve common issues:
- Check All Connections: Ensure that all wiring connections are secure and free from corrosion or damage.
- Verify TDC Alignment: If the LED does not turn off during the baseplate adjustment, double-check that the crankshaft is properly aligned at TDC.
- Inspect the Timing Cover: Ensure that the timing cover is installed correctly and that the ignition module is securely mounted.
- Consult the Manufacturer’s Documentation: If the issue persists, refer to the manufacturer’s installation guide for additional troubleshooting steps.
Compatibility and Model Support
The Dyna S ignition system is compatible with a wide range of Harley-Davidson models from 1970 to 2003. The supported models include various Softail, Dyna, Tour Glide, and Sportster variants. For a complete list of compatible models, the following information is provided:
- Softail Models: FLSTF, FLSTN, FLSTS, FLT, FLTC, FLTCU, FLTCUI, FLTR, FX, FXB, FXD, FXDC, FXDG, FXDL, FXDWG, FXE, FXEF, FXLR, FXR, FXR2, FXR3, FXR4, FXRC
- Sportster Models: XL1200C, XL883C, XL883R, XLCH, XLCR, XLH1000, XLH1100, XLH1200, XLH883, XLH883DLX, XLH883HUG, XLH900, XLS, XLT, XLX 1000
The system is also compatible with various Wide Glide, Fat Boy, and Heritage models. However, late-model bikes with OEM electronic ignitions may require a separate mechanical advance unit for full compatibility.
Performance and Benefits
The Dyna S ignition system is designed to deliver several performance benefits, including:
- Increased Power Output: By producing a stronger and more consistent spark, the system can improve engine performance and throttle response.
- Reduced Vibration: Users have reported that the system helps reduce highway-rpm vibration, leading to a smoother and more comfortable ride.
- Improved Reliability: The system is built to withstand the demands of high-performance riding and is guaranteed against defects in materials and workmanship.
- Ease of Use: The preprogrammed ignition curves and adjustable settings make it easy to fine-tune the system for different riding conditions and engine setups.
Conclusion
The Dyna S ignition system is a high-performance upgrade for Harley-Davidson motorcycles that offers a range of benefits, including increased power, improved reliability, and reduced vibration. The installation process is relatively straightforward, and the system is designed to integrate with the existing wiring and components in most models. By following the step-by-step installation guide and verifying the connections, users can ensure a successful upgrade that enhances their riding experience.
This guide has been compiled using information from manufacturer documentation, installation instructions, and technical specifications provided in the source material. The Dyna S ignition system is a proven upgrade that is suitable for both stock and modified Harley-Davidson models, making it a valuable addition to any rider’s motorcycle.