Powerdynamo brings new ignition & light
to your vintage motorcycle
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Powerdynamo brings new ignition & light |
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| Assembly instructions for system 71 67 499 00 |
Version 22.10.2007 |
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Please read these instructions fully before starting work on your bike or any modification on the supplied system. Also, please note the remarks on the information page for this system. |
| If you have no expertise for the installation have it done by an expert or at a specialist's workshop. Improper installation may damage the new system and your motorcycle. | |
| Before you order a system, please check against the section "you
should have received those parts" whether all parts wanted are in
the kit. You might want to order a puller tool,
light bulbs,
fuse, horn,
flasher
unit etc. Never use anything other than a puller tool M27x1.25 to pull the new rotor again. In case of damage to the rotor as a result of use of other (unsuitable) tools and facilities, the warranty claim expires! |
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If you have access to the Internet, see those instructions online. You get larger and better pictures by clicking onto them and possibly updated information. System list at http://www.powerdynamo.biz |
| The rotor is sensible to blows during transport. We therefore double pack the material (box inside box). Should the system have been despatched to you via a reseller and arrive not packed like this, please inform us. | |
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Before assembly, please always check the magnets (try to push
them aside with your fingers).
After impact the glued in
magnets might have broken loose, sticking to the rotor however by
magnetic force, so that one does not notice right away. During run there would be considerable damage as a
result. Before putting the rotor to the engine, please make sure that its magnets have not collected metal objects such as small screws, nuts and washers. That equally would lead to severe damage. |
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To disengage your new rotor again, you will need a puller M27x1,25 (part 99 99 799 00).
Note: never use a claw puller, a hammer or any other device, that will shake the magnets off. |
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You should have received those parts:
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| Make sure your motorcycle rests securely, preferably on an elevated work bench and that you have good access
to the front of the engine. You will have to turn the front wheel
from time to time for better access. Disconnect your battery and take it out of the motorcycle. |
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Disconnect all alternator cables and remove the alternator. |
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Do not remove the ignition system. It has to stay in place unaltered. |
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Put the preassembled stator plate instead of the original alternator on
the motor case.
Lead the cable upwards through the opening in the rear part of the motor case. |
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Place the rotor onto the crankshaft and fasten it with the screw M8. Do
not forget to place the washer underneath.
(Picture shows plate from our complete - ignition - system!) |
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Fix the new regulator/rectifier to the frame of the motorcycle. You may
use the space now liberated by the diode plate. dimensions of this regulator are 80 x 55 x 40mm (drawing see here) |
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Connect the parts as shown in wiring diagram g-only: |
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The new regulator/rectifier has a compact plug with 6 positions, of which one is not used (before November 2007 it were two). From November 2007 onwards a female plug cover fitting to this plug is delivered. Into this female plug you have to insert the following wires (which have terminals that snap into the plug): | |
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The two black cables leading from the generator ... |
... connect to pins 1/4 of the new regulator (from there equally black wires lead inside the unit). It does not matter which wire connects to which of the both terminals (1/4) as they carry alternating current. |
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| * | The new brown cable with the round eye terminal ... |
... connects pin 3 of the regulator unit (from there equally a brown wire goes inside the unit) with the negative pole of the battery or (in case you drive without battery) to ground (chassis). |
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The new red cable with the round eye terminal ... Take care: |
... connects to pin 5 of the new regulator (from there equally a red wire goes inside the unit). Here your regulated positive voltage comes out to connect to battery plus, or (in case you drive without battery) to the voltage input terminal of the main switch (ignition lock, German bikes: pin 51/30). |
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| Make sure that you have a 8A-fuse between battery and vehicle circuitry. | |||
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The green/red wire at pin 6 of the new regulator ...
Remark: |
... is for the charge control light.
You connect there the wire that formerly did run from the control light to
the original regulator. |
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| The charge light control function is based on a transistor switch and is an additional function. Even if that should fail, the regulator might still be in ok working condition. Simple check: have the engine running, turn lights on, disconnect the battery. If you have bright lights the unit is ok. | |||
| Remarks for 6 Volt systems: |
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Finally - and before installing the battery and before the first kickstart - please re-check carefully all connections and fitments against the wiring diagram. Do check battery and light bulbs for correct voltage (12V). Should something not work, please consult our trouble-shooting guide on our homepage. As a first step disconnect the blue wire from the coil and re-test. |
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IMPORTANT: During crank shaft repair the dynamo shaft is often
machined and gets shorter. The result is a rotor sitting lower, possibly
touching now with its rivets the stator coil. The result is a destroyed
stator and ignition failure. For more detail and how to check see (online) here. |
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Important safety and operating information for dynamo only systems |
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Safety first! Please observe the general health and safety regulations motor vehicle repair (MVR) as well as the safety information and obligations indicated by the manufacturer of your motorcycle. |
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After installation, please check tightness of all screws. If parts get loose during run, there will be inevitably damage to the material. We pre-assemble screws only loosely. |
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Give the freshly installed system the chance to work, before you start
to check and test values, or even worse before you make changes thought
to be sensible by you without having seen the system run. Our parts have been checked before delivery. You will not be able to check much anyway. At any rate do refrain from measuring the electronic regulator. You risk several damages to the inner electronic there. You will not get any sensible results from the operation anyway. Check ground connections carefully and, to be on the safe side and for testing, put an additional ground wire from the regulator directly to the engine block. |
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Never do electric welding on the bike without completely disconnecting all electronics. |
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Electronics are very sensitive to wrong polarity. After work on the system, do check correct polarity of the battery and the regulator. Wrong polarity creates short circuits and will destroy the regulator which is for negative earth only. |
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When you handle the new rotor, take care not to damage its magnets. Refrain from direct blows to the circumference of the rotor. For transport never put the rotor over the stator. Observe our information relative to transport of the material. |
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It is a good idea to cover the rotor in a thin layer of oil to reduce the risk of corrosion. |
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Never use a claw puller or a hammer to disengage the rotor. Its magnets might become loose in the event. We offer a special puller screw for disengaging the new rotor again (see assembly instruction)! |
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Should the motorcycle not be in use for some longer period, please disconnect the battery (so existing) to prevent current bleeding through the diodes of the regulator. Though, even a disconnected battery will empty itself after a while. |
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Please do observe those remarks, but at the same
time, be not afraid of installation. Remember, before you, thousands of
other customers have successfully installed the system. Enjoy driving your bike with its new electric heart! |
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