Thicky setting up a DMC2

Dave,

If you're getting a spark when switching on/off, the unit at least is recieving power, is connected to ground and the coil conections are most probably OK.

Check your pick-up wiring, probably something amiss there.  Position "0" is for test purposes only, if correctly connected you should have a continuous spark at all three plugs (optical pick-up only).  For initial set-up and strobing, postion "1" should be used.  Once this is set, you can change around the various curves as you like.

What model bike, Dave?

piet
 
Dave,

Power supply to the coils should be cut off automatically after only a few seconds of the engine being stopped.  Supply is restored the instant the crank starts turning again.

Of course the power supply needs to be upheld before starting, and as you're not getting a spark and the engine isn't starting, the coils most probably won't be switched off.  The power has to go somewhere, so it heats up the coil brackets... :D

As you have removed the ignition /alternator base plate to install the extra charging coil, I'd check the pick-up wiring for shorts(the isolation breaks up, holds up OK till it's handled in some way or another, then the problems start!) and the wiring where it exits the alternator housing.

HTH,
piet
 
Piet, thank you for your replies.  I am totally at a loss and frustrated with this. I am not a complete idiot when it comes to electrics and have a pretty good understanding of motor controls but do not claim to be an expert.
  When I had the base plate off I checked the wiring on the pick up coils very closely and did not like the look of the insulation as it was flaking off the connecting wires to the pick up coils.  I have pretty good soldering skills so I very carefully removed and repaired and replaced the connection.  From the base plate the wiring for the charging coils and the pick up coils are now in good condition. The pick up coils using a quality meter show 59-60 ohms each, but I do not know what they are suppose to be.
The only wiring on the bike at present is only what is required to get it to run and its pretty straight forward to connect the DMC (7 wires total).
  I tested the new rectifier before installing,  black to ground,  red/white to power supply  and the charging coils to the 3 yellow wires the brown wire is not connected but I will once I get it running.
 I connected  the regulator as per the diagram provided by John Wilson that can be found on this site , I used the second diagram method.
 When trying to elicit a spark to the plugs with the screwdriver movement away from the pickups I did notice that the magnetic pull of the pickups is very weak ...is it normal.   I am at a loss so maybe a call to Wolfgang in Canada might help.
  Would love to get it going as the weather here is perfect for riding and I have a week of work coming up in 2 weeks. Help. Cheers Dave
 
Dave,

+/-60 Ohms is OK.

When doing the screwdriver trick, be sure to bridge both magnetic poles of the pick-up.  Magnetic pull is not very strong.  Rectifier should have no influence on DMC function. You could rig it up directly to the battery on constant loss to eliminate any other factors.

piet
 
Dave

Have you wired the primary side of the coils correctly?

DMC's have a positive (+12V) supply to the coil and the coil switching is done on the -ve side.
Some ignitions switch the positive side and the other terminal on the coil goes to earth.

If you get them arse about they won't work. Been there, done that.

Cheers,
Cam
 
Progress update.  I was not able to work on the bike for the past week, 7 in a row 12 hour shifts pretty much sapped away any life left in me.  I gotta win the F.....g Lotto!
  I spoke with Wolfgang and then with Uwe Witt in Germany got a couple of tips one of which was not to worry too much about not getting a spark with the screw driver test more important is to connect the blue and yellow wires to the + power supply and check for a continuous strong spark at the plugs which there was.  Whoohee!
  Following the advice of both Wolfgang and Uwe (vite down vot I am telling yoo. I did)  I rechecked the wiring from the pickup coils and sure enough when I had repaired the wiring on the coils I had transposed (fancy word for mixed up) one of the wires. Thank you Mr Witt.
I corrected my mistake pulled the battery from my Toyota as the bikes battery is not the best (new Odyssey on order) connections made hit the starter and.....the bitch is back, fired right up, bloody loud aren't they?!
  Now it needs some fine tuning and to make the wiring connections respectable and permanent and I should be back on the road with a new spark in me bike!  Many thanks to all who contribute their knowledge and experiences to this site, Cheers Dave.
 
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