Installing a Dyna 3000 Ignition

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Written by Randy Fox (randysgym)   
Sunday, 02 September 2007

Cutting a Dip Switch Access Hole

Note: The following steps, refer to cutting a dip-switch access-hole in the battery box. They only apply if you think you might want to change your Dyna 3000 dip-switch settings in the future, and you'd prefer to remove the battery to make your changes rather than pull the ignition module out of the bike, through the steps shown above.

Disconnect the negative (right side) battery cable.

Remove the rubber hold-down strap from the top of the battery.

Remove the battery.

Remove the two, small bolts and spacer-washers from the battery box side-tabs.

Next begin working the battery box up and out:

  • There are 3 little tabs at the rear of the box to free.
  • There are two large tabs at the rear, but they only show themselves as the box comes up.
  • Be careful to gently move any snagged wires out of the way.
  • Take your time to avoid over-stressing any wires.

Once the box is out, note the attachment of the rubber strap at the front of the box. Then remove it.

Yamaha Road Star Battery Box Graphic

Next, mark the box for cutting the dip-switch access hole. I cut mine according to the diagram shown above.

Yamaha Road Star Battery Box cut for new Ignition

Now use a Dremel, drill, or any other appropriate cutting tool to cut and smooth a rectangular hole through the front side of the battery box. I finished mine with a flat file, to square the corners and smooth any rough lines and edges.

Once the hole has been cut, test-fit the Dyna 3000 into its holding tabs in the battery box. Orient the unit so that the dip-switches become hidden by the front edge of the battery box, and the connector sockets are pointed to the right--when viewed from the front of the battery box.

Dyna 3000 cut through Road Star Battery Box

Now look from inside the battery box to be sure your access hole makes the dip-switches visible and accessible. If the dip-switches are not visible, be sure the Dyna is positioned all the way against its final stop, furthest to the left--when viewed from the front of battery box. If you can see that the Dyna is squarely seated against its final stop, and the connector sockets are oriented correctly--yet no dip-switches can be seen through the access hole you cut--you may have cut the hole in the wrong place.

Once your test-fit is satisfactory, remove the Dyna 3000, and set it aside for now.

Put the rubber strap back on the front of the battery box. Then reinstall the battery box into its mounting hole. Be careful of the large wiring bundle at the rear of the battery box mounting-area. It must be tucked into the 'tunnel' at the rear of the battery box.

As you work the battery box down, push the 2 large tabs--located along the rear-- down into the mounting hole. And then push the 3 little tabs--also at the rear--in to their little holes as you finish lowering the box in to position.

Be sure the large wiring bundle at the rear of the battery box mounting-area is tucked under the 'tunnel' along the rear of the battery box. Also be sure the negative (right side) battery terminal is visible.

Now secure the battery box by installing the two spacers/washers and two bolts into the bolt holes at the left and right sides of the battery box, and tighten. The battery box should be flush and square. If not, do not force it; look for a cause and fix it, otherwise you could short a wire or break some plastic.



 
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