TOPIC:

Where to start? Last summer I bought my 1978 KZ1000 it turned out to be a big restore project.
1.I replaced the handle bars which required me to disassemble the forward controls and remove the wires from the handle bars and replace them.

2. I replaced the coils with a Dyna 30ohm set (green)

3. Replaced the points with a Dyna S ignition system

4. Reassembled it all and SNAP when I turn on the ignition my main fuse blows that is connected to the ignition circuit.

WHY?

I checked all wires for shorts re-read the instructions searched the forums. Any idea what I did wrong?
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Post edited by: XL777, at: 2007/04/17 14:53

disconect the wires to your ignition and coils and see what happens,then start plugging things in one at a time and see what pops your fuse;)

First, explain why you would have to remove forward controls to replace the handlebars. That is truly an interesting statement!

OK on to the problem at hand. Wireman's advice is fine IF you have some idea what to disconnect. I suspect some mis-wiring took place with the ignition. To start, there are two little skinny wires coming off the Dyna S. What did you wire them to? They provide voltage to the Dyna S. If you connected them to the wrong wire and it wasn't hot, then BANG the main fuse blows. How did you connect your coils up? Could the coil wires be touching the bracket the coils are molded to or some other ground? I guess what I would do is this...

1. disconnect power from the Dyna S.
2. turn on key and see if the fuse blows
3. if it blows, then the coils are likely hooked up wrong - if it doesn't blow, then the coils are probably not the culprit but the Dyna S is.

just now I disconnected the coils and its still blowing something.

here is how it is hooked up.
from the Dyna S there is a RED, BLACK and WHITE wire that connects the the COILS. The RED wire connects to the two RED/YELLOW wires going to the COILS, and the BLACK wire connects GREEN wire on the RIGHT COIL. The WHITE wire is going to the BLACK wire on the LEFT coil.

Also it says something in the instructions about not leting the screw head that mounts the wires to the coils touch the space how is that possible

I just disconnected the DYNA S and I still get a bright light on my tester

here is some pictures

Post edited by: XL777, at: 2007/04/17 16:00

new to pics here

Post edited by: XL777, at: 2007/04/17 16:04

How do you post more then one picture in a reply?

I can take more if needed

The yellow/red dual out above your valve cover is the connection for the coils. Dyna give you a cheesy blue splice connector to splice into the wire terminating in the dual out coil connection. I would strip some insulation back on the yellow/red and tie in the RED wire from the Dyna S to power it. I would solder the connection and cover it with heat shrink.

There should be two wires coming out of the dual out connector... These should go to each of your coils. Doesn't matter which. It doesn't matter which lug they go on but I like to put them on the lug not under the bracket arm. These are hot connections when you switch on the power. Make sure they are lying flat and the exposed part of the wire isn't touching the frame or the bracket or something.

There are two pickups on the Dyna S. The RIGHT pickup coil on the Dyna S is the 2/3 pickup. Trace the wire coming off it to the right hand ignition coil and this will be your 2/3 ignition coil. Make sure the plug wires are going to the 2 and 3 plugs. The plugs are numbered 1 to 4 left to right as you sit on the bike. The other wire comes off the left pickup coil and is the 1/4 wire and should eventually hook to the left coil which becomes the 1/4 coil and should have the wires hooked up to the 1 & 4 plugs.

If you removed the leads from the coils and turned the key on and popped the fuse, it is very likely the splice to the dual out connector is bad or something along those lines.

Last, when you put on the pickup that spins on the crank end, did you orient the magnet in the pickup correctly? I always forget to do this and end up have the plugs fire 180 degrees out.