When you experience problems after you have installed a powerdynamo
system, please do not jump to the conclusion that the material must be
faulty! You otherwise deprive yourself of the sometimes quite easy
option to find and solve the problem quickly. We provide a lot of information
in our knowledge base and we will advice you on trouble shouting with our
- The failure rate of our material is less than 0.1%.
- 95% of material returned to us for checking as assumed to be
faulty is absolutely working normally.
- In the vast majority of cases customers contact to us that they
have no or only a weak spark ignition
is working properly, but general setup of the motorcycle is faulty or
they try to test in unsuitable ways
Unfortunately we hear often from customers "I got the material
checked by a specialist" or "i did check the material" and it is
Whatever had been checked there, it may not only have been useless, but could be
downright dangerous for the material. Here
you find an overview of what you could check and how.
None of our ignition parts carries battery voltage and battery voltage
should never be introduced there (except our ignitions labelled
clearly battery ignition)
we write in all our instructions:
At any rate do refrain from measuring
the electronic components (such as ignition coil, regulator and advance
unit). You risk severe damage to the inner electronics there. You will not
get any tangible results from the operation anyway.
After the problems have been solved, we always ask the customer to tell us
what the reason was.
Here the most frequent problems found:
- Ground, ground, ground. Problem number 1 is bad or missing ground!
this can not be stressed enough. Though we warn in our instructions
not to rely on the frame as electrical conductor many customers do so
- and get problems.
- Problem number 2 are spark plugs and/or
spark plug caps.
Here we hear again and again that new ones had been used, plugs tested in
other engines have been used etc.
Still, this is a major problem. See info here
- Blue wire, blue wire, blue wire. Very many problems are connected to blue kill
wire and cut-off relay.
relay is wrongly connected to the main
switch and does NOT bring the needed voltage - as a result ignition
remains off. ground connected to the blue switch off wire by a
defectice kill switch, unsuitable relay,
damaged wire, shorting somewhere to ground. We even had customers who
thought the blue wire has to be connected to ground by design.
- carburettor, carburettor, carburettor. we read again and
again "i can exclude the carb, it is new, it has been redone, it
has been cleaned" only that the customer found at the end that
indeed it was the carburettor (and/or the air filter).
- main switches are a reason also, bad or wrong switches are
rather frequent (notably in the age of chinese replicas).
- Wrong understanding of how high energy spark looks like and unsuitable
testing methods leading to such findings as "i
have only a weak spark"
- Very many customers suspect the regulator when they encounter
the regulator however does not have any role in ignition. Only
connection between lighting and ignition is - so installed - the
relay. See info here
- As the customer would have just installed the Powerdynamo ignition,
he tents to suspect it as the cause for engine starting/running
problems. Experience however shows that in most cases causes for
problems are not in ignition material, but other
- If your engine sports increased compression, changed stroke, changed
timing etc than you should not be surprised that you encounter
problems. Our material is made for stock
configurations, not unknown tuning configurations.
- Number 1 problem is faulty wiring in motorcycle grid outside
Here nothing is impossible. After all, you have an old motorcycle with
often unknown past.
Frequent finds have been:
- missing wire from new regulator plus and/or battery to main switch
- bad or wrong main switch and terminals of same
- bad batteries which consume all
produced energy but do not load (internal short circuit) - quite
- We had short circuits on tachometer bulb inside tachometer that
happened when bulbs got changed
from 6 to 12V, so problem was not visible before
- Problematic is always when motorcycles had originally both
alternating current (AC) for headlight and possibly taillight as well
as direct current (DC) for battery charge and flashers. Those
two part grids have to be combined in the fully DC environment of
the Powerdynamo (except AC systems). This problem can be really
tricky. We will gladly assist the customer in this if we get a copy of
the original wiring from him.
- often there are dead batteries on
board (sometimes even shopnew dead ones). they will burn all
arriving voltage into heat, forcing the system to break down.
- one of the black wires for lighting might be damaged
under the stator coil and shortcircuit to ground (notably in
internal sensor units)
A further frequent problem are customer modifications on wiring and
connector plugs of Powerdynamo components. In very many cases we get
material back for testing where wires have been cut, welded or connected
by various, often unsuitable connectors.
- note that welding may damage electronics
- crimping of replacement terminals is often not good without access
to proper tools
- re-wiring always bears the danger of short circuits and wire mix
- last not least we always have additional efforts to test such
material as connectors are not standard any more (if not missing at
- it is simply not understandable that first things many customers do
during installation is to cut of our plugs only to install badly
The number of customer complaints of ignition failures is
manifestly higher in spring. We get such reports as "last year all was
ok, now i wanted to drive again, did not start".
- battery low?
- carburettor blocked by dirt particles?
- petrol over the moon (it ages very quickly!)?
- airfilter moist?
Also we see a significant increase in problem reports during heat
waves. We get such reports as "after only a few kilometers engine
suddenly stopped and refused to restart".
- mostly spark plus and cap issues
- carburation issues (pressure inside carb due to heat)
finally, please consider that other than ignition related problems might
be the cause of what you experience. See our
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