Dyna Coil Installed - Crack-O-Matic Toast

[montmil]

Pretty simple install, really. Had to take a cut-off wheel to an overhead and empty wiring plug attach point so the new coil would fit comfortably, but that was no biggie. The Motorrad Elektrik aluminum coil bracket is the essence of simplicity and function.

New coil, wires, caps and plugs. My cow is getting happy. Got some more cleaning to do. Hello, Simple Green.



Dated the coil install with a Sharpie in case I forget.




... and the original coil. The circular pattern of cracks were hidden by the snake's nest of wiring.

[Rob Valdez 79 R65]

Nice pictures!  I had never seen a cracked coil before.  I had no idea where exactly the cracks occurred.

Good idea writing the date on the coil!


Don't forget the black zip-ties for your frame.

[montmil]

Nice pictures!  I had never seen a cracked coil before.  I had no idea where exactly the cracks occurred.  Good idea writing the date on the coil!  Don't forget the black zip-ties for your frame.

Neither had I until I used an inspection mirror and my MiniMag flashlight! Spotted the cracks while working on the front end wiring harness.

Thanks for the pic compliment. I'm still old school when it comes to photography. When I want really good images, I go with my 35mm film cameras. For most stuff, particularly for image postings, I shoot an Olympus FE-230 with 7.1 megapixel. The camera has a "close up" macro setting. That helps me look good. I'm also quite fond of the classic No. 2 pencil and a legal pad, preferably white.

For this and other forum postings, I scale the pics to around 4x6 inches so they don't take up so much "space". What's that word I'm looking for? I'm not all that compuKer savvy.

About the Dyna coil photo... Notice the two loose red wires running out the left side of the image. These are from a PO and I can't determine what they are doing and/or why.

Note both are tapped into existing, clipped off wires; one of the red wires - guessing red wire was all the PO had - is connected to a clipped off black original wire and runs to a grounding screw holding a relay in place. Strange. I thought das Germans liked brown for earth.

The other red wire is spliced into another clipped off original green wire and terminates in a tap into an existing green wire entering the fuse box. Very strange.

Note that there's also a clipped off brown wire - ground, most likely - and an odd orange-color wire. All exit the rubber tubular wiring loom. In the pic, the rubber tube looks like a rusty frame member.

I dunno what's going on here. No orange wires in my Clymer wiring diagram. I do like the full color printing in this manual. Much easier to trace wires.

Any ideas? I'm tempted to just remove them, but then again...

Got zips. They are the UV stabilized black numbers. Will zip 'em after cleaning up the wire harness.

Monte

[Rob Valdez 79 R65]

The blue clips on the right look after market, as well.
Is the main wiring harness stock???  Does it have any of the stock wiring colors in it?

[Bob_Roller]

Does anybody know what kind of service life to expect out of the Dyna coil ?

[nhmaf]

It does appear that someone has been adding on some electrical tidbits to that wiring harness.
The photos from my coil replacement thread last year shows what I believe is an all-original
wiring harness (for an 82 model):

http://suraklyn.com/yabb/YaBB.pl?num=1195434246/3#3

You can see in the picture that my original coil was also cracking in a circular pattern about the end.
All the coils with part number ending in "200" are subject to this problem, you can see that my oiriginal
coil and monte's were of this batch.   A later OEM replacement coil part number ending in "203" (I think)
supposedly stopped the cracking problem, but I went with the Dyna Brown coil and have been very happy
with it.  Starting has become even easier with some new plug wires..

[Bob_Roller]

The upgraded OEM replacement coil ends with the numbers 426, and is red and black, I installed one of these in 1994 when my original gray and black coil failed, it wasn't cracked, the secondary windings went 'open', infinite resistance.

The upgraded coil started giving me problems after about 9 years, the primary windings had low resistance, and was causing hard starting below 55 F.

I blamed the 10% ethanol that was added to our local fuel at about the same time.

So far no problems with the Dyna coil, I have left the bike outside in 22 F. weather, and no problems starting.

[montmil]

The blue clips on the right look after market, as well. Is the main wiring harness stock???  Does it have any of the stock wiring colors in it?

Oh, yes... several "custom" wiring touches I've noticed. As far as I can tell, the main harness is stock. Repeat... "as far as I can tell." Much of the correct color BMW wire is still in place and terminates at the correct bit of hardware. OEM wrapping of the wire is vintage and mostly untouched. I've checked it against a Clymer color plate wiring diagram.

The first item I came across was the ignition switch. It was not a BMW switch and had been custom fitted to the bike. A cutting torch - uh huh - was used to enlarge the opening in the metal switch bracket. A rice bike on-off keyed ignition was rather crudely attached with a typical ring mount. The wiring was cobbed together at the back of the switch. Earlier PO - not the seller - must have boosted a few cars in his day. At least he demonstrated a skill.

The bike also has an empty wiring socket with approx eight wires terminating in a male socket. It appears OEM with a black plastic case, rubber boot and properly wrapped wire loom. Properly wrapped means with the BMW fabric tape that has gone crumbly. It may be an accessory socket for... a side hack?

A few of the odd wires do not appear to go anywhere. At least not electrically. It's a challenge but also sorta fun. An Indiana Jones quest to simplify and make lighter.

At any rate... the bike lights off with a quick touch of the starter button and, with the new coil and HT leads and such, runs great. No complaints. And as my bride says to any and all, "Monte's always working on a project." And after seeing a bunch of Harley folks at the Hard Eight BBQ in Stephenville, Texas, she also allowed that, "We're not going to dress like trash." OK, Sweetie. Can I buy the new Metzlers now?

Stay tuned. Film at eleven.

[beemer]

Pretty simple install, really. Had to take a cut-off wheel to an overhead and empty wiring plug attach point so the new coil would fit comfortably, but that was no biggie. The Motorrad Elektrik aluminum coil bracket is the essence of simplicity and function.

New coil, wires, caps and plugs. My cow is getting happy. Got some more cleaning to do. Hello, Simple Green.



Dated the coil install with a Sharpie in case I forget.




... and the original coil. The circular pattern of cracks were hidden by the snake's nest of wiring.

Did you have starting problems with the old coil before you changed to the new one,or was it because you spotted the cracking and decided to change it,my bike has become hard to start when hot,i'm wondering what's causing it,the carbs have been set and balanced,and she runs fine when she's running!!but stop her,and she's hard to start again.

[montmil]

[/quote] Did you have starting problems with the old coil before you changed to the new one,or was it because you spotted the cracking and decided to change it,my bike has become hard to start when hot,i'm wondering what's causing it,the carbs have been set and balanced,and she runs fine when she's running!!but stop her,and she's hard to start again. [/quote]

Starting, hot or cold, was not an issue. The ignition miss on the left cylinder lead me to replace the vintage HT leads, plugs and plug caps. Mike's XS  http://www.mikesxs.net/  provided the complete setup for a bargain price.

Further inspection discovered the cracked original coil. I received good counsel here on the Disorganized R65 site when I was advised to be very suspect of a 27 year old ignition coil. Right they were.

Hot start issues can be maddening. If you're sure the Bings are "binging" properly, I'd start looking at ignition sources.

Monte

[beemer]

Yes,iv'e changed the plugs,HT leads it's electronic ignition,so that makes me think coil,any other thoughts from you?cheers,J.

[montmil]

Yes,iv'e changed the plugs,HT leads it's electronic ignition,so that makes me think coil,any other thoughts from you?cheers,J.

A small inspection mirror and a flashlight. Check the ends closely.

[beemer]

Yes,iv'e changed the plugs,HT leads it's electronic ignition,so that makes me think coil,any other thoughts from you?cheers,J.

A small inspection mirror and a flashlight. Check the ends closely.

Ends of the coil?

[montmil]

Yes,iv'e changed the plugs,HT leads it's electronic ignition,so that makes me think coil,any other thoughts from you?cheers,J.

A small inspection mirror and a flashlight. Check the ends closely.

Ends of the coil?

Yes. The gray and black OE coil is kinda rounded in its shape. I found the cracks in a circular pattern at the forward end of the coil. Check the posted photos again.

[Rob Valdez 79 R65]

The bike also has an empty wiring socket with approx eight wires terminating in a male socket. It appears OEM with a black plastic case, rubber boot and properly wrapped wire loom. Properly wrapped means with the BMW fabric tape that has gone crumbly. It may be an accessory socket for... a side hack?

All of our bikes came with "blanks".  One, I know of, is for optional 4-way flashers.  Another may be for heated handgrips or the driving lights.  I am pretty sure none of them are for sidecars.

Here is my picture of my '79 sockets, identified, as best as I could figure: