Best leads for mini coils?

[LeeJackson]

Hi guys

Fired up the bike again today and still having some problems with spark. Number 4 is obviously not firing properly as plug is quiet wet. I have dyna 2000, with mini leads and they came with the Carbon dyna wires. I'm pretty sure the problem is with the leads, or more likely how I assembled them I was never very happy with the spark from the get go and I'm not really sure how they are supposed to work with the huge resistance they have.. Is anyone else running this setup ok?

I'm thinking to change the leads for something more traditional with a copper conductor to eliminate the carbon wires.

Question is can I use a copper lead with these coils ok? Something like Taylor leads? Is it a good idea to change for these?

Thanks
Lee

[Big Fluff]

Lee.

I have just had exactly the same problem as you, misfiring etc. after fitting brand new Dyna 2000, Dyna 'mini' coils and Dyna carbon trace leads to a customers Z1R-TC Turbo. I know exactly what you need to do in order to overcome the problem!

Firstly however, no you can't use copper core leads, these will not work with the coils you have.

This corrective job is a pain in the arse, but one you will need to do in order to overcome the problems you're having.

Firstly, the problem lies at the connection lead ends to the coils, and NOT the ends that go the the spark plugs.
I take it like me, you have fitted the 90 degree ends to the leads where they fit into the coils?
If so, use a small suitable non-sharp point to slide between the HT lead and the angled rubber cover and squirt some WD40 in there. Then, whilst holding the actual connection with small long nose pilers through the open end, slide the covers back to reveal the steel metal 90 degree crimp connection.
Once this is exposed, uncrimp the connection and remove from the HT lead.
You will notice that there is no hole for the centre core of the HT lead to go through, relying only on the core being crimped between the outer HT silicone covering and the crimp connection. This really isn't good enough and you have to wonder why on earth that the straight connectors that come with the Dyna HT lead kit have holes for the centre cores, but not the 90 degree angled ones

The solution is to drill a 2mm hole through the steel connection in the centre as hopefully clear in the attached picture (arrow).
Once you have done this, remove enough outer HT lead to expose around 1¼" of centre core.
Next pass the centre core (shown in yellow) through the 2mm hole, then wrap it around over the steel connection then back under the outer part of the HT lead and finally crimp it into position. Slide the very tight 90 degree angled rubber cover back over, again using plenty of WD40 coz they're tighter than a nuns beaver!
You'll need to do all 4 connections I'm afraid but the results should fix your problem.

If the picture below isn't big enough, PM me with your EMAIL address and I'll send a big image to you okay.

Regards, Will

[Big Fluff]

[ZedHead]

Have you raised this with Dyna Will? It makes no sense for there to sell these with no connection to the centre core

[ZedHead]

:shock: Have you raised this with Dyna Will? It makes no sense for them to sell these with no connection to the centre core

[LeeJackson]

Hi Will,

I actually used the straight connectors but I didn't wrap them through the hole as the instructions just said to double back and crimp, but it never seemed right to me! Anyway super helpful info, I'm off to the garage to have a play now...

[LeeJackson]

So that's two leads done, but unfortunately I seem to have lost two of the 90 degree crimps! So will have to order some more and finish off after. Will update on results! Cheers

[LeeJackson]

Well I managed to get new crimps, bought a new correct crimping tool, re-terminated everything with the extra loop and still the same issue. The Spark still looks pretty weak and orange. Not the nice big bright blue spark I would expect. (although I did read a few articles saying colour is not important) but it should still be a big bright spark of some sort.

I even took a Taylor lead and tried connecting that just to check and it made no difference, so it looks like I have another issue... I checked all earths and all seems good.. Could it be a lack of power to the coils? I always assumed not as I had replaced all wiring and the switchgear.. Except the ignition switch.. Any way to test for this at all?

[LeeJackson]

Seem to be getting 12.3V to the coils so should be enough power getting thru..

[Big Fluff]

Hmm.. might be worth testing the continuity of the high and low tension circuits. Not sure what the figures are for Dyna mini coils, maybe Rob Zed1015 might know?

[LeeJackson]

I'm going to try and run an earth back to the battery directly as suggested by a few when I'm back at the weekend. Let's see what that does..

[Big Fluff]

An earth from where? The coils do not rely on a direct earth. This is done through the ignition system module or pulsars so I can't see this being of any benefit.

[LeeJackson]

Hi Will, I was thinking from the mounting posts, but doing some reading earlier I also noted that this was mentioned as not important. So guess that will make no difference then? Earth running straight back to the dyna 2000 unit when it fires I belive? Which is then in turn earthed straight back to the battery? So if not that I'm running out of ideas. I assume the actual dyna 2000 unit doesn't need to be earthed other than the connection to the battery?

[ZedHead]

Will, you are correct the LT side of the coil is pulsed to earth through the ignition unit. However the HT side is permanently earthed to the frame through the bracket. Powder coating is an excellent insulator in these areas

[LeeJackson]

Ok so I required everything, re-earthed everything and spark seems to be brighter, although it could be my imagination anyway I fired it up again and still didn't seem to be running quiet right. So checked the timing again and adjusted, set to 35 Deg advance. Now it seems better.. But still at low revs it's not right. When I get up above 3k it seems to clear and run better. But pipe 4 still seems cold compared to the rest.. Any ideas? Carbs are brand new 34 mikunis and everything else is new. Plenty of fuel getting in because the plugs seem a little wet to me.