logo

my specialty:12volt conversion kits for BMW /2 motorcycles

INSTALLING THE POWERDYNAMO (MZ-B)

12 VOLT CONVERSION KIT ON A 1966 BMW R69S

 

Wiring it all together:

PowerDynamo component wiring layout

The photograph above shows the PowerDynamo system components and the associated electrical connections described in this section. The main components in the system are the Stator (shown with rotor removed), the Ignition Coil, The Electronic Advance Unit, and the Voltage Regulator.

The electrical connections to be made during installation are numbered in the photograph above as follows:

This may all seem a bit daunting, but the plugs are such that it is difficult to make a mistake--if the plug fits, it's correct. The only minor hassle is installing the wires in the female side of connection plug 2 (I likely will construct this plug for you in the kits I ship).

stator wiresstator plugcompleted plug

You will need the PowerDynamo wiring harness. We are going to make a couple of connections in the breather compartment under the top engine cover. But first, note in the left photo above that the stator coil wires are sent by the factory loose "to facilitate the wire exiting through the often small openings in the engine casing." I don't think it would be a problem on a BMW /2 pushing the assembled plug through the the opening at the top of the engine gear case into the breather compartment under the top engine cover. However, with the stator wires introduced to the breather compartment, It only takes a minute or so to build up the plug 2 using the female blank plug included in the factory kit. The trick is to make the female plug match the wiring in the male plug (red to red and black to black--does not matter which black) in the Powerdynamo harness.

We connected the empty plug to the Powerdynamo wiring harness plug (1 red and two black wires) and then I used needle nose pliers to insert the wire spades to match the colors in the counterpart plug in the wiring harness. The photo on the right is a better view of the completed plug. I likely will just do this step before I ship out a kit so you will not have to bother.

coil connection inside engine top cover

HT spark plug cablesThe second connection to complete in the breather compartment is the black plug 3 from the ignition coil which mates with a white plug from the PowerDynamo wiring harness. This plug makes a connection from the ignition coil to the electronic advance unit.

The photo on the right above shows the connection tucked away in the breather compartment and the Powerdynamo wiring harness grommet pushed into the notch at the forward top of the compartment.

This is a good time to push the HT leads 7 out the side of the engine case. Smear a little dielectric or other grease on the cable and the job will be much easier.

If you're wondering where the old main wiring harness has gone to, it is draped out of the way unharmed. We'll return to it in a later step.

 

 

Next we'll made a couple of connections at the electronic advance unit.

electronic advance connection Electroniv advance unit

The photo left above shows the two plugs that connect the electronic advance unit into the PowerDynamo wiring harness; the advance unit is out of sight to the right and the wiring harness to the left. The lower plug 5 with the white, yellow, and red wires connects to the plug in the PowerDynamo wiring harness that has white, green, and red wires as shown in the photo above. The upper plug 4 from the electronic advance unit with the red, blue/white, and white wires connects to the Powerdynamo wiring harness plug with red, white, and yellow. Note in the photo that the male/female relationship is reversed in the two plugs making it impossible to connect the two plugs incorrectly.

The photo on the right above shows the two leads from the electronic advance unit running up to and plugging into the PowerDynamo wiring harness which has been zip tied to the bike frame.

Voltage Regulator Layout VR plugdiagram

The connection from the PowerDynamo wiring harness to to voltage regulator 6 requires you to insert the two loose spaded black wires (see the insert in the center photo above) from the PowerDynamo wiring harness into the male side of the plug a positions 1 and 4, upper and lower position on the left side of the plug shown on the diagram right above. The center photo shows the two black wires partially inserted into the proper positions. It makes no difference which black wire goes into the upper or lower position as these wires carry alternating current. The red wire 8 connects to the positive post on the battery. The black wire 9 connects to the negative post on the battery.

blue wireterminal 2main wiring harnesscharge light wreRed charhing light connection

The blue wire 10 in the PowerDynamo wiring harness is the ignition kill connection. You may run it up into the headlight shell and connect it to post number 2 on the main terminal board (shown in second photo). We did not wish to run extra wires into the headlight shell and the alternative of connecting the blue wire 10 to the brown/black striped wire in the motorcycle main wiring harness (10 in the center photo) which completes a connection to post number 2 on the terminal board. We also elected to connect the blue/red stripe wire 11 from the voltage regulator to the blue wire (11 in center photograph) in the motorcycle main wiring harness whichcompletes a connection to the red charging light in the headlight shell. We previously removed this wire from terminal 61 on the generator. You also have the option of just running the blue/red stripe wire 11 directly to the charging light terminal in the headlight shell (shown in the far right photo above).

Finally the two thick red wires on either side of the blue wire in the center photo above should now be connected if you have not already done so. The two red wires earlier removed from the generator complete the connection between the motorcycle battery and the main switch on the terminal board in the headlight shell. As mentioned earlier, if you do not splice these two wires together, you will have no lights.

Once all the the connection were made, we zip tied the PowerDynamo wiring harness to the bike frame. As we wanted to leave the R69S in a condition so that the machine could be easily converted by the owner (or more likely his heirs) back to the the original 6 volt configuration, we rolled the motorcycle main harness wiring that had been pulled back out of the generator and magneto into a circle and zip tied it to the back side of the electronic advance. We were still able to easily fit the fuel tank back onto the motorcycle to begin the initial timing procedure.

Setting the ignition timing:

setting the initial timing
You will need a timing light to complete the ignition timing. But, before installing the 12v battery and starting the motorcycle, carefully recheck all the electrical connects and fasteners, and confirm that you have replaced all lights on the motorcycle with 12v bulbs. these include the following components:

In addition, if you have bar-end signals you will need two 12v bulbs and a 12v flasher signal indicator relay.