Ignition system on '77 kz650

I already forgot what the blue connector was for. Yes, the dyna is very nice on the fwy. I'll need to sort out this bad idling though but why didn't it ilde bad right away?

This is my bike.

This is my bike.

EC2 if Bluemeanie is correct then you need to remove that blue connector (I never did use it in the first place on good advice from Bluemeanie and others) and solder the two Red wires in the Dyna supplied cable to the same wire you were connectored to.

Alternatively, if you have installed the WG Coil Repowering Mod then the choice is easy. Connect to the output of the relay. That would be pin 87 and if you used my colour code it should be the Red wire.

Again alternatively, if you have not installed the WG Coil Repowering Mod then you need to connect to a source of switched +12 Vdc battery voltage before it goes through too may old connections and switches. I would solder into the Blue/White-Marker wire as it comes out of the Ignition switch. If that's too hard follow the Blue/White wire until it joins up with the Brown circuit wire(s) and solder into the Brown wire.

BTW, if your bike was not running well before then this will not eliminate the symptom, the cause lies elsewhere and you will need to troubleshoot further. However, if it was in fact running well before then this may eliminate the symptom.

How did you time the bike? Static with a light bulb as indicated in the Dyna installation instructions or using a timing light or both?

Best of success.

PS
Better luck with posting. :ohmy:

Thanks, I'm going to try soldering tomorrow or Sun. The bike used to run really well. I did the timing using the voltmeter instead of a light bulb. After all 1-4 and 2-3 cylinders were timed, I checked it with a strobe light.

I re-wired and the bike ran fine for 100 miles or so but today it popped when being started. When I finally got it running it ran fine but has no power. By pulling the plugs one at a time, I noticed cylinders 2 and 3 are not firing. This is back to square one when I had the Martek 440 ignition module and the Accel coils(CDI type). Now I have stock coils with the Dyna S ignition module. Something is causing the left coil(cyl 2-3) and maybe even the ignition module to malfunction. Any clue?
I'm really frustrated. Does anyone know of a good mechanic in the Long Beach, Ca area?

eaglecrash2 wrote:

I re-wired and the bike ran fine for 100 miles... cylinders 2 and 3 are not firing... have stock coils with the Dyna S ignition module....

Would first install brand new plugs in cyl 2-3 and re-test, as one faulty plug may cause both to mis-fire.

If not already done, would check connection where signal wire from right-hand Dyna-S module connects to coil primary wire.

Could experiment by swapping coils to determine whether non-firing issue moves from 2/3 to 1/4 (and indicate the present 2/3 coil is defective).

Old plug wire or defective cap, or bad connection at wire>cap or cap>plug, could cause the cyl 2-3 misifire.

Might also consider installing a pair of new green Dyna coils, and new Dyna solid core plug wires with pre-installed caps.

Good Luck!

EC2, Patton's advice is right on the money IMHO.

A few other things to consider... the recommended troubleshooting strategy is usually as follows:
1) Compression (check/repair/re-check)
2) Ignition (check/clean/repair/replace/re-check)
3) Carburetion (check/clean/adjust/replace/re-adjust)
- in that order.

Remember, you may have more than one layer of faults. Would recommend the WG Coil Repowering Mod to eliminate any intermittent Coil powering issue... and it can drastically improve reliability at about $10 USD. See WG here:

LINK: WG COIL MOD

Here is how I adapted this modification to my '77 KZ650-B1:

LINK: Relay K1

Best of success.

Thanks folks...will give it another shot. I'm kicked in the ass bad here!! kzrider.com/components/com_kunena/templa.../emoticons/angry.png

eaglecrash2 wrote:

Thanks folks...will give it another shot.
I'm kicked in the ass bad here!!

One thing that kicked me for awhile was an internal fray
in the 12 volt supply wire that's permanently connected
into the stock coil. The wire looked and seemed perfect
from the outside. But was broken inside and making
intermittent connection.

Could test integrity of inside wire by manipulating the
wire while ohm-checking the primary side of coil.

In the end, I finally got fed up contending with and wondering
about the ancient old worn out stock coils, and opted to just
throw new parts (Dyna coils and wires) at the problem.
Been working just fine ever since.

Good Luck!