Powerdynamo brings new ignition & light 
to your vintage motorcycle

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IMPORTANT: Please do read these instructions fully before starting work on your bike or any modification on the supplied system.
Version 71 96 499 CMF
 (CEMEC)
If you have no expertise on installation have it done by an expert or at a specialist's workshop. Improper installation may damage the new system and your motorcycle. 
If a battery is used, it must be 12V and must be connected with its negative pole to ground! (Never with the positive, even if the original system was!)
If you have access to the Internet, see these instructions online. You get larger and better pictures by clicking onto them at http://www.powerdynamo.biz
First of all, make sure that the unit is suitable for your application. You should consider the following points:
  • Check version (here for CEMEC).
  • If a battery is used, it must be 12V and must be connected with its negative pole to ground.
  • If no battery is used you must use a smoothing condenser, otherwise light output will be less than normal.
Please note that some characteristics of the unit differ from the original magdyno:
  • It delivers 14.4V DC (the standard voltage for a 12V system).
  • The male threading at the main shaft differs to original and is M8x1 (special nut supplied).
These parts are in the basic kit:
  • the alternator itself
  • fuse 6A and holder
  • M8x1 nut 
  • securing ring
  • 2 countersunk screws M3 and one M5


    You need to know what original dynamo version your CEMEC has.

If you want the unit to replace a Magneto France on your CEMEC, you need additionally

  • adapter
    part 71 96 004 CMF 

  • sprocket
    part 71 96 007 CMF 

    You may use the sprocket from the NOVI version as an alternative, but our replacement sprocket has 10 teeth (as the Magneto France sprocket) and brings therefore more revs and hence more output than the NOVI sprocket.

  • holder
    part 71 96 005 CMF

If you want the unit to replace a NOVI on your CEMEC, you need additionally the 
holder, part 71 96 006 CNO

 

Alternatively you may modify your existing holder base (for the diameter of 76mm).
You may use the original NOVI adapter with spring and seal and the original sprocket.

Alternatively you may use our adapter
part 71 96 004 CMF (same as for Magneto France version) and our sprocket 71 96 007 CMF

Never put the original nut onto the shaft. This would damage the metric thread M8x1 on the shaft.
Preparation of the installation (engine side)
  • Remove the existing dynamo as per relevant maintenance manual.
  • Remove existing 6V battery.
  • Replace 6V ignition coil by 12V version.
  • Replace 6V bulbs with 12V bulbs of same wattage.
  • Clean dynamo mounting area and inspect for condition.
    If you have a Magneto France version, put the 2 holder adapter over the original holders.
  • The horn should work okay for short burst on the 12V system. If it sounds distorted it may need adjusting.
Preparation of the installation (dynamo side)
  • Fit the adapter (either the new or the NOVI original) and the sprocket. 
Place the prepared new alternator onto the engine, same way you did before with the stock dynamo. Do not forget to put the seal washer.

Check that the sprocket it correctly aligned for the chain. Tighten the chain as per manufacturers instructions and fasten the unit with the strap.

The alternator gets electrically connected via the single red wire and ground contact of the unit to the engine block. Please use the supplied fuse when connecting the alternator (see wire diagram).
Wiring:
Wiring is quite simple. Only very few changes in the original wiring are needed.
  • Disconnect the old regulator (no longer needed).
  • Connect the wire from the Amperemeter which is now free (was before to old regulator) via the new fuse (Please do not forget!) to the red wire of the new unit.
Lighting voltage is outputted via the long red wire coming out of the unit. This carries 12V plus. Insert into this wire the supplied 6A fuse. Minus is internally connected to the units housing which hence requires solid electric ground connection.
You will not be able to turn the shaft by hand. You must place a sprocket on the shaft. When turning the shaft you will notice the resistance of the magnets which is higher than in the stock dynamos.

Having mentioned the internal resistance, there is no need for worry that your engine can not pull it, or will suffer a loss of power. Your stock dynamo has the same resistance once it gets load, it runs only freely if there is no electric drain on it.

During operation the unit will warm up noticeably, especially at the alloy ends. This temperature may (with motorcycle not moving) climb up to 85°C (you should be careful when touching the hot unit). This heat will not damage the electronics and is actually not produced by the electronics or near them. The heat comes from the aluminium. Similar to a microwave oven, the strong magnetic field causes the alloy particles to rub against each other, heating themselves up.
There is no reason to open the unit. There are no serviceable components inside.

Unscrewing the rotor mounting plate could lead to severe damage and will void the warranty.

If you must know how it looks inside - here is a photo.
The unit has a unique identity number embossed into the front face.

The 2 holder screws are sealed. If you open them the seal will break and your warranty will be void.

If you suspect a defect in the unit, you must return it to Powerdynamo for inspection and (if needed) repair.

#

Important safety and operating information!

# Give a newly installed unit a chance to work (burn in) before beginning to check and test values, or even worse before making changes you may think necessary without having seen the unit run.
Our parts have been checked before delivery. There is very little an owner can check. At any rate do refrain from trying to measure internal values.
# Due to the very strong magnetic field of the unit it should not be held in close proximity to heart pacemakers or other electronic medical devices in case of interference with these devices.

#

Never do electric welding on the bike without completely disconnecting all electronics.
# Electronics are very sensitive to incorrect polarity. After work on the system, do check correct polarity of the battery. Incorrect polarity creates short circuits and will destroy the regulator.
# Please do observe these instructions, but at the same time, do not be deterred from the installation. Remember, other customers before you have successfully installed the unit. Enjoy driving your bike with its new electric heart.
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