Clutch's 1982 KZ750 E3 Cafe

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07 Feb 2012 17:23 #502628 by clutch
Replied by clutch on topic Clutch's 1982 KZ750 E3 Cafe
Checked out fuel system, and all looked good today. All four float levels were within spec and the rubber fuel line looked to be in good condition, so I don't think it's a fuel issue anymore. I was going to take the bike out for a ride after checking all that, so I had it warming up in the driveway for a few minutes. All seemed well until I walked back into the garage to grab a helmet. The bike died! Started it back up and it had dropped 2 cylinder again. So now I'm fairly certain the Dyna-S is failing due to heat. If I recall correctly, that is a common issue with the stock electronic ignition, so I would assume the Dyna-S can have that problem as well. Anyone know for sure?

Southern Maryland, USA

1980 KZ250 LTD (traded, but still missed)
1982 KZ750 E3 (Cafe Project) (Dyna-S, Dyna Coils, V&H 4-1, K&N Pods, 6 Sigma Jet Kit, Acewell Computer, Woodcraft Clip-ons, Custom Rewire)
1966 A1 Samurai (Restoration Project)

Wish List:
KZ1000 P (For a "touring" bike)
Z1 (need I...

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07 Feb 2012 17:54 #502631 by ramtough_63
Replied by ramtough_63 on topic Clutch's 1982 KZ750 E3 Cafe
I emailed the guys at Dyna since this seems to be a common problem one that I may still have I hope they get back with me with a reasonable explalnation or at least some other cause for us to look for incase they wont own up to the abnormal intermittant brakdown of signal

1978 KZ1000 A2
Thrown Together To Ride Til Winter
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07 Feb 2012 19:52 - 07 Feb 2012 19:54 #502653 by Patton
Replied by Patton on topic Clutch's 1982 KZ750 E3 Cafe

clutch wrote: Checked out fuel system, and all looked good today. All four float levels were within spec and the rubber fuel line looked to be in good condition, so I don't think it's a fuel issue anymore. I was going to take the bike out for a ride after checking all that, so I had it warming up in the driveway for a few minutes. All seemed well until I walked back into the garage to grab a helmet. The bike died! Started it back up and it had dropped 2 cylinder again. So now I'm fairly certain the Dyna-S is failing due to heat. If I recall correctly, that is a common issue with the stock electronic ignition, so I would assume the Dyna-S can have that problem as well. Anyone know for sure?

This may result from plug fouling during warm-up due to over-rich mixture from whatever cause such as too rich pilot circuit or prolonged choke application, and is especially apparent where battery charge is questionable or full voltage isn't reaching the coils for whatever reason.

Have many times experienced dropped cylinders as the ride begins, then ride for a while with the headlight clicked OFF to give the battery a chance to recuperate, and when cylinders resume combustion, turn the headlight back on, and boom-shakalaka, no more problems for duration of the ride.

Would try more quickly eliminating choke, and using the throttle to keep engine running during warm-up.

Good Fortune! :)

1973 Z1
KZ900 LTD
Last edit: 07 Feb 2012 19:54 by Patton.

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07 Feb 2012 19:57 #502656 by clutch
Replied by clutch on topic Clutch's 1982 KZ750 E3 Cafe
I had already removed choke several minutes before it died on me. Idle mixture should be fine as I had leaned it down a few months ago from being slightly rich. Also, it was idling with headlight off, so I don't think the battery is the issue. Plugs, coils, coil wires, Dyna-S and every wire on the bike are all new. I checked all wiring in the ignition circuit and replaced anything questionable, so I don't think it's that. Anyone know of a bench test for the Dyna-S? I would love to be able to measure it somehow.

Southern Maryland, USA

1980 KZ250 LTD (traded, but still missed)
1982 KZ750 E3 (Cafe Project) (Dyna-S, Dyna Coils, V&H 4-1, K&N Pods, 6 Sigma Jet Kit, Acewell Computer, Woodcraft Clip-ons, Custom Rewire)
1966 A1 Samurai (Restoration Project)

Wish List:
KZ1000 P (For a "touring" bike)
Z1 (need I...

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07 Feb 2012 20:18 - 09 Feb 2012 01:46 #502660 by Patton
Replied by Patton on topic Clutch's 1982 KZ750 E3 Cafe

clutch wrote: ...was idling with headlight off, so I don't think the battery is the issue....

Battery condition doesn't particularly matter during warm-up.
And it doesn't matter whether headlight is off or on during warm-up.

Where there's tendency to fuel-foul, battery condition matters mostly after warm-up. And if charge is marginal, may cause dropped cylinders.

While sitting there warming up at choked fast idle, the plugs are exposed to fuel fouling, and when the cylinder drops, the inadequate spark from the low battery is insufficient in the non-firing cylinder.

It's just that in my experience this is a more common experience than a failed Dyna-S. Not to say it's not a faulty Dyna-S in this particular instance.

Good Fortune! :)

1973 Z1
KZ900 LTD
Last edit: 09 Feb 2012 01:46 by Patton.

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08 Feb 2012 23:15 #502889 by ramtough_63
Replied by ramtough_63 on topic Clutch's 1982 KZ750 E3 Cafe
Got a reply back from Dyns I really didnt expect them to condemn there product but was hoping for a little more info


(from Dynatek)
Hello Aaron.
The issues you report are not common with the Dyna-S. To cite my own
experiences, I had a Dyna-S on a motor for over 19 years and 45,000 plus miles
with no problem at all. Keep in mind that this was many years before I came to
work at Dynatek. Having installed too many to recount over the last 25 years,
I had never seen failures and this is why I continued to use them, up to and
including today.
The majority of Dyna-S failures we have seen are the result of either using
the incorrect coils (wrong ohm rating), charging system issues (under and over
charging) or loose connections within the Dyna-S system and electrical system,
including the battery positive and negative. It is relatively rare to see a
Dyna-S fail for no reason. In all fairness, the Dyna-S is a man made,
electronic part and a failure may randomly occure, but not very often. The
actual return rate is just under 4 of every 100 sold.
When you do replace your coils, be sure they are rated at no lower than 3.0
ohms.
Thank you,
Larry Nelson
Technical Support
Dynatek
1-800-928-DYNA (3962)

1978 KZ1000 A2
Thrown Together To Ride Til Winter
Facebook Page
Free Range Custom Art


1982/83 750R/GPZ
1984 Goldwing 1200 Interstate
1982 Yamahopper QT50
Previous
2 79 HD sporty XLH
02 HD FLSTS Heritage
60's HD Hummer
70's Honda 550 Four
70 Yamaha 100
and various enduros dirtbikes minibikes...

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14 Feb 2012 16:48 - 14 Feb 2012 16:50 #503977 by clutch
Replied by clutch on topic Clutch's 1982 KZ750 E3 Cafe
I decided to give the "blipping the throttle to warm it up rather than using choke to long" method a try today to see if I was fouling out a plug or two. It ran well for a few minutes, and then the same thing happened. I watched the fuel closely though. It appears that fuel flows (trickles really) ONLY when the bike is running. This is with a manual petcock in the on or res setting, and with or without the tank cap open. It appears fuel flow really is the issue, and I'm stumped as to why it won't fill up the filter like it used to. Should I drain the tank, pull the petcock and inspect it? This is a new petcock (few hundred miles), so I don't think it's gone bad already. What do you guys think?

EDIT: Could it be that crappy clear plastic fuel line from the tank to the filter? I know they cause issues, but I didn't think flow was one of them.

Southern Maryland, USA

1980 KZ250 LTD (traded, but still missed)
1982 KZ750 E3 (Cafe Project) (Dyna-S, Dyna Coils, V&H 4-1, K&N Pods, 6 Sigma Jet Kit, Acewell Computer, Woodcraft Clip-ons, Custom Rewire)
1966 A1 Samurai (Restoration Project)

Wish List:
KZ1000 P (For a "touring" bike)
Z1 (need I...
Last edit: 14 Feb 2012 16:50 by clutch.

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14 Feb 2012 17:00 #503980 by 531blackbanshee
Replied by 531blackbanshee on topic Clutch's 1982 KZ750 E3 Cafe
sounds like your petcock is plugged up clutch.

i would pull it from the tank and insure it was clear.

leon

skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!

billybiltit.blogspot.com/

www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work

kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0

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14 Feb 2012 17:02 #503982 by clutch
Replied by clutch on topic Clutch's 1982 KZ750 E3 Cafe
I will check that out next time I get motivated to do something with it. What would clog it so quick? Crappy gas? Foreign object in the tank (where ever it may have come from)?

Southern Maryland, USA

1980 KZ250 LTD (traded, but still missed)
1982 KZ750 E3 (Cafe Project) (Dyna-S, Dyna Coils, V&H 4-1, K&N Pods, 6 Sigma Jet Kit, Acewell Computer, Woodcraft Clip-ons, Custom Rewire)
1966 A1 Samurai (Restoration Project)

Wish List:
KZ1000 P (For a "touring" bike)
Z1 (need I...

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14 Feb 2012 18:55 #504000 by 531blackbanshee
Replied by 531blackbanshee on topic Clutch's 1982 KZ750 E3 Cafe
you should be able to pull the hose off your petcock and turn it on and the gas should flow freely from it.


leon

skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!

billybiltit.blogspot.com/

www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work

kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0

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14 Feb 2012 19:33 - 14 Feb 2012 19:34 #504006 by Patton
Replied by Patton on topic Clutch's 1982 KZ750 E3 Cafe
Could also open the float bowl drain screw to see whether fuel flows and keeps flowing freely from the bowl. As this assures flow from inside tank on through everything and into the float bowl.

Good Fortune! :)

1973 Z1
KZ900 LTD
Last edit: 14 Feb 2012 19:34 by Patton.

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06 Mar 2012 00:07 #508028 by clutch
Replied by clutch on topic Clutch's 1982 KZ750 E3 Cafe
Hey guys...haven't been on lately. I pulled the gas tank yesterday and after a few minutes of checking the "little things", discovered that the problem (hopefully the only one) is a clogged/faulty fuel filter. Got a couple on the way from Z1, but am hoping to find one locally so I can ride and test it out tomorrow.

Southern Maryland, USA

1980 KZ250 LTD (traded, but still missed)
1982 KZ750 E3 (Cafe Project) (Dyna-S, Dyna Coils, V&H 4-1, K&N Pods, 6 Sigma Jet Kit, Acewell Computer, Woodcraft Clip-ons, Custom Rewire)
1966 A1 Samurai (Restoration Project)

Wish List:
KZ1000 P (For a "touring" bike)
Z1 (need I...

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