Author Topic: Coil issue  (Read 196 times)

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Offline 1977_cb550k

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Coil issue
« on: January 31, 2026, 02:05:30 PM »
I’ve had a Dyna ignition system running in my Cb550 k3 with no problems for 12months+ (in fact it’s a massive improvement over points). 

I had to replace my coils six months ago and bought a generic aftermarket set.  Ran perfectly until the last 2 weeks.  I keep getting intermittent cutout on one coil (I suspect it’s the 1+4) which cuts back in when I ‘wobble’ some wires while riding. 

Here’s what I’ve done/checked.
- cleaned and tightened the contact spades. They are tight and spotless
- insulating tape around the wires (heaps of it)
- checked that the black wires are on + and the green wires are on the - male connections for both coils. 

I’ve heard Dyna needs stronger coils but given its intermittent I figured the coil hasn’t failed. 

Anyone had similar issues and can suggest a fix?
1977 CB550k3

Offline HondaMan

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Re: Coil issue
« Reply #1 on: January 31, 2026, 02:26:18 PM »
No, the Dyna doesn't need 'stronger' coils: it's pretty amazing that your 550 is even supporting the Dyna triggers because they draw more than 2x the normal current as points.

If you bought you new coils from 4into1.com, you're not alone. Those are failing almost as fast as riders can install them: the ones from PartsNmore are very good, though (#17-6823). I use them in many rebuilds.
« Last Edit: January 31, 2026, 04:07:30 PM by HondaMan »
See SOHC4shop.com for info about the gadgets I make for these bikes.

The demons are repulsed when a man does good. Use that.
Blood is thicker than water, but motor oil is thicker yet...so, don't mess with my SOHC4, or I might have to hurt you.
Hondaman's creed: "Bikers are family. Treat them accordingly."

Link to Hondaman Ignition: http://forums.sohc4.net/index.php?topic=67543.0

Link to My CB750 Book: https://www.lulu.com/search?adult_audience_rating=00&page=1&pageSize=10&q=my+cb750+book
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Offline newday777

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Re: Coil issue
« Reply #2 on: January 31, 2026, 03:25:17 PM »
"when I ‘wobble’ some wires while riding."
Where are the wires that you wobble? At the steering neck?
Stu
Honda Parts manager in the mid 1970s Nashua Honda
My current rides
1975 K5 Planet Blue my summer ride, it was a friend's bike I worked with at the Honda shop in 76, lots of fun to be on it again
1976 K6 Anteres Red rebuilding project, was originally my brother's that I set up from the crate, it'll breath again soon!
Project 750s, 1 K2, 4 K6, 1 K8, 1 F1, 1 F3
2008 GL1800 my daily ride and cross country runner

Prior bikes....
1972 Suzuki GT380 I had charge of it for a year in 1973 while my friend was deployed and learned to love street riding....
New CB450 K7 after my friend returned...
New CB750 K5 Planet Blue, demise by ex cousin in law at 9,000 miles...
New CB750 K6 Anteres Red, to replace the totaled K5, I sold this K6 at 45k in 1983, I had heavily modified it, many great memories on it and have missed it greatly.....
1983 GL1100A, 1999 GL1500 SE, 1999 GL1500A

Offline 1977_cb550k

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Re: Coil issue
« Reply #3 on: January 31, 2026, 03:33:51 PM »
Thanks Hondaman. The coils I bought are from eBay, they look different to the partsNmore version.
https://ebay.us/m/W5RRdx
I used new NGK plug caps rather than the ones in the coil kit.   

Is intermittent cutout a typical symptom of a bad coil? I assumed it would just die?
« Last Edit: January 31, 2026, 03:50:17 PM by 1977_cb550k »
1977 CB550k3

Offline 1977_cb550k

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Re: Coil issue
« Reply #4 on: January 31, 2026, 03:37:14 PM »
"when I ‘wobble’ some wires while riding."
Where are the wires that you wobble? At the steering neck?
W
Yes, wobbling the clutch/other heavy cables (there’s two together) or reaching under the tank to the coil wires.

Not the ignition leads themselves.
« Last Edit: January 31, 2026, 03:51:14 PM by 1977_cb550k »
1977 CB550k3

Offline 1977_cb550k

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Re: Coil issue
« Reply #5 on: January 31, 2026, 03:45:37 PM »
Ok, now there’s more to this puzzle. I installed a new battery last week and after a 1.5hr return ride on the freeway this morning between 6.45-8.45am, the battery is low. You can see the detail in this image.

1977 CB550k3

Offline HondaMan

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Re: Coil issue
« Reply #6 on: January 31, 2026, 04:40:03 PM »
Normally, since in the USA we are forced to run with the headlight (and tail and instrument lights, by default) ON all the time, the 500/550 alternator is strapped to the max in the normal bike's wiring/loads arrangement. With the OEM headlight (40/45 watts) and taillight (8 watts) ON, there is only about 11 watts (9.6 watts, 0.8 amp) left to charge the battery. If the bike is stopped at a stoplight, it is draining the battery (with points ignition) about 2.4 amps with the lights ON, until about 4000 RPM when it breaks even and begins to charge again. This is with the OEM coils aboard, which are 0nly charging 1 at a time with points ignition.

When the Dyna triggers are used, this changes the picture quite a bit. The Dyna charges BOTH coils (instead of just one at a time) all the time except during the very short period when the trigger magnet passes the pickup. This adds one whole coil's current to the constant load picture. The Honda coils are 4.3 ohms (2.8 amps each at 12.0 volts), so the bike is forced to try to charge more current than the alternator can even make when the lights are ON with the Dyna. Typically this means the bike's battery will drop lower and lower until the voltage falls far enough for the overall current load to stay at maximum charge rate, which I've found is somewhere around 11.4 volts in a fully-functional 500/550 system. This isn't healthy for the battery, as it encourages sulphation to start on the lead plates when the chemistry falls short of the needed ions.

I've seen this lead to some serious troubles in the 500/550, including wiring fires when someone tries to "fix" this without removing the Dyna. Adding things like a lithium battery and its required "smart" charging regulator is not practical, as their charging method requires that before the battery will accept a charge, it must be "tickled" until the chemistry will accept a charge: this isn't how these bikes' charging systems work, nor can they be made to work that way. This requires a "smart" voltage regulator and enough run & charge time that the bike would end up being useful only for (as example) all-out Interstate touring every day, with a short startup period with no charge at all, followed by a long charge time: rather impractical in real life with traffic lights, stop signs, and uneven engine speeds. This system was designed to run with the lights OFF in daylight (1971-72 era), and ON occasionally for night riding. It was the US DOT who changed the lighting rules AFTER these bikes were designed (1973) that created the problem.

So, I'm sorry to say that in the USA with lights ON all the time, the only way to make a Dyna S [almost] work is with an LED headlight and taillight bulb (which isn't bright enough in a red lens) and freeway touring to work and back, and Dyna's 5-ohm coils instead of normal ones. The other way is to (re)use points (and [many also use] my Transistor Ignition, which was created precisely to solve this problem and stop the frequent points maintenance needs, in 1973) and at least OEM coils (4.3 ohms), or the Dyna 5-ohm coils. The latter has improved many 500/550 bikes by just adding them to the bike with points, too.

I don't intend to use this as a 'forum' to advertise my Ignition, but rather as an explanation of why it was created in the first place, and specifically for (my) CB500 and CB750 in 1973. It was to reduce the points maintenance that these SOHC4 bikes had greatly increased because they were so happy to run all day - which was novel in the 1970s. ;)
See SOHC4shop.com for info about the gadgets I make for these bikes.

The demons are repulsed when a man does good. Use that.
Blood is thicker than water, but motor oil is thicker yet...so, don't mess with my SOHC4, or I might have to hurt you.
Hondaman's creed: "Bikers are family. Treat them accordingly."

Link to Hondaman Ignition: http://forums.sohc4.net/index.php?topic=67543.0

Link to My CB750 Book: https://www.lulu.com/search?adult_audience_rating=00&page=1&pageSize=10&q=my+cb750+book
Link to My CB500/CB550 Book: https://www.lulu.com/search?sortBy=RELEVANCE&page=1&q=my+cb550+book&pageSize=10&adult_audience_rating=00
Link to website: https://sohc4shop.com/  (Note: no longer at www.SOHC4shop.com, moved off WWW. in 2024).

Offline scottly

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Re: Coil issue
« Reply #7 on: January 31, 2026, 05:53:11 PM »
Ok, now there’s more to this puzzle. I installed a new battery last week and after a 1.5hr return ride on the freeway this morning between 6.45-8.45am, the battery is low. You can see the detail in this image.
Interesting. Where did that image come from, and at what point was the voltage measured? The fact that wiggling the wires makes the problem come and go sounds like a poor connection somewhere local to the wiggling? BTW, the 500/550 alternator puts out 110 watts@2000 RPM and 200 watts@5000 RPM. ;)
Don't fix it if it ain't broke!
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Offline newday777

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Re: Coil issue
« Reply #8 on: January 31, 2026, 07:58:40 PM »
"when I ‘wobble’ some wires while riding."
Where are the wires that you wobble? At the steering neck?
W
Yes, wobbling the clutch/other heavy cables (there’s two together) or reaching under the tank to the coil wires.

Not the ignition leads themselves.
The reason I ask is that You need to sort out where exactly the loose joint is, if it's at the steering neck, you need to open up the main harness and find the weak wire. The wires there at the bend get flexed back and forth with turning the bars back and forth, and the outter harness sheath over the harness is stiff now from age, and sometimes a wire breaks in there intermittently as you are experiencing. I have had to find a broken wire(s) cut the wire at the break, solder and heatshrink the repair, then wrap the harness back together with electrical tape.
There are companies that supply new harness sheath(you would need to de-pin the multipin connectors to run the wires in the new sheath)

Does your bike have headlights on all the time or do you have a switch to turn them off and on?
I see you are in Australia and I'm not familiar with the Australian bike controls and your bike could be an American import ???
Stu
Honda Parts manager in the mid 1970s Nashua Honda
My current rides
1975 K5 Planet Blue my summer ride, it was a friend's bike I worked with at the Honda shop in 76, lots of fun to be on it again
1976 K6 Anteres Red rebuilding project, was originally my brother's that I set up from the crate, it'll breath again soon!
Project 750s, 1 K2, 4 K6, 1 K8, 1 F1, 1 F3
2008 GL1800 my daily ride and cross country runner

Prior bikes....
1972 Suzuki GT380 I had charge of it for a year in 1973 while my friend was deployed and learned to love street riding....
New CB450 K7 after my friend returned...
New CB750 K5 Planet Blue, demise by ex cousin in law at 9,000 miles...
New CB750 K6 Anteres Red, to replace the totaled K5, I sold this K6 at 45k in 1983, I had heavily modified it, many great memories on it and have missed it greatly.....
1983 GL1100A, 1999 GL1500 SE, 1999 GL1500A

Offline 1977_cb550k

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Re: Coil issue
« Reply #9 on: January 31, 2026, 10:08:01 PM »
Quote
Does your bike have headlights on all the time or do you have a switch to turn them off and on?
Yes, in Australia the law is to have motorcycle headlights on all the time (same as USA).

And the screen grab is from a Bluetooth battery monitor I have on the battery. These are awesome devices if you haven’t seen them before. Provides constant monitoring of your battery, crank tests and warnings straight to your phone - very good!
https://amzn.asia/d/7RlRYkf
« Last Edit: January 31, 2026, 10:12:35 PM by 1977_cb550k »
1977 CB550k3

Offline PeWe

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Re: Coil issue
« Reply #10 on: January 31, 2026, 10:26:21 PM »
The new coils have too low resistance?
My CB750 drained the battery rather quick with Dyna-s and Dynatek 3 ohm coils (green).
This with headlight on which is a must for safety and by law.

I could return them to shop and get 5 ohm versions (black). Then no battery drain issue.
No issue with Honda stock coils either. New coils ca 5 years ago.
CB750 also has a stronger charging system than CB500
CB750 K6-76  970cc (Earlier 1005cc JMR Billet block on the shelf waiting for a comeback)
CB750 K2-75 Parts assembled to a stock K2

Updates of the CB750 K6 -1976
http://forums.sohc4.net/index.php/topic,180468.msg2092136.html#msg2092136
The billet block build thread
http://forums.sohc4.net/index.php/topic,49438.msg1863571.html#msg1863571
CB750 K2 -1975  build thread
http://forums.sohc4.net/index.php/topic,168243.msg1948381.html#msg1948381
K2 engine build thread. For a complete CB750 -75
http://forums.sohc4.net/index.php/topic,180088.msg2088008.html#msg2088008
Carb jetting, a long story Mikuni TMR32
http://forums.sohc4.net/index.php/topic,179479.msg2104967.html#msg2104967

Offline 1977_cb550k

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Re: Coil issue
« Reply #11 on: February 01, 2026, 02:29:03 AM »
Thanks all. Seems I need to find 5 ohm coils and replace.  I’m going to suck it up and pay the premium price for Dynatek coils.  :-\ (they are 3.5x the cost of others in au!)

Then there’s probably a few other things to check:
- trim ignitions leads and check/replace the spark plug caps
- check/clean the ground wire.

For completeness, I’d still like to find the source of the intermittent cutouts which suggests a connection issue.  Will report back when I find it!
1977 CB550k3

Offline newday777

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Re: Coil issue
« Reply #12 on: February 01, 2026, 03:57:10 AM »
Quote
Does your bike have headlights on all the time or do you have a switch to turn them off and on?
Yes, in Australia the law is to have motorcycle headlights on all the time (same as USA).

And the screen grab is from a Bluetooth battery monitor I have on the battery. These are awesome devices if you haven’t seen them before. Provides constant monitoring of your battery, crank tests and warnings straight to your phone - very good!
https://amzn.asia/d/7RlRYkf

I haven't seen that battery monitor,  not available according to the link.

Have you changed out the light bulbs to LED bulbs yet for power savings??
Stu
Honda Parts manager in the mid 1970s Nashua Honda
My current rides
1975 K5 Planet Blue my summer ride, it was a friend's bike I worked with at the Honda shop in 76, lots of fun to be on it again
1976 K6 Anteres Red rebuilding project, was originally my brother's that I set up from the crate, it'll breath again soon!
Project 750s, 1 K2, 4 K6, 1 K8, 1 F1, 1 F3
2008 GL1800 my daily ride and cross country runner

Prior bikes....
1972 Suzuki GT380 I had charge of it for a year in 1973 while my friend was deployed and learned to love street riding....
New CB450 K7 after my friend returned...
New CB750 K5 Planet Blue, demise by ex cousin in law at 9,000 miles...
New CB750 K6 Anteres Red, to replace the totaled K5, I sold this K6 at 45k in 1983, I had heavily modified it, many great memories on it and have missed it greatly.....
1983 GL1100A, 1999 GL1500 SE, 1999 GL1500A

Offline scottly

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Re: Coil issue
« Reply #13 on: February 01, 2026, 07:33:32 AM »
Thanks all. Seems I need to find 5 ohm coils and replace.  I’m going to suck it up and pay the premium price for Dynatek coils.  :-\ (they are 3.5x the cost of others in au!)


Are your coils less than 5 ohms?
It appears your charging system isn't working, rather than an issue with coils. Also, you said it was fine until two weeks ago. The intermittent miss may be due to inadequate voltage to power the ignition system.
Don't fix it if it ain't broke!
Helmets save brains. Always wear one and ride like everyone is trying to kill you....

Offline Mark1976

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Re: Coil issue
« Reply #14 on: February 01, 2026, 09:05:38 AM »
Thanks all. Seems I need to find 5 ohm coils and replace.  I’m going to suck it up and pay the premium price for Dynatek coils.  :-\ (they are 3.5x the cost of others in au!)


Are your coils less than 5 ohms?
It appears your charging system isn't working, rather than an issue with coils. Also, you said it was fine until two weeks ago. The intermittent miss may be due to inadequate voltage to power the ignition system.
   I agree with scottly, you ought to do some basic testing to see if something hasn't failed. I've been there, and those readings you display are way low. The intermittent cut out is a symptom of low voltage with the dyna ignition, especially during acceleration. Load test the battery, if its bad replace it and start the diagnostic process....
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Offline 1977_cb550k

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Re: Coil issue
« Reply #15 on: February 01, 2026, 01:27:53 PM »

Are your coils less than 5 ohms?
[/quote]

Yes, they were generic eBay coils so I assume 3ohms. 
1977 CB550k3

Offline bryanj

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Re: Coil issue
« Reply #16 on: February 01, 2026, 02:20:43 PM »
NEVER ASSUME test with a multimeter but do remember to short the leads togeter and subtract that number
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Offline scottly

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Re: Coil issue
« Reply #17 on: February 01, 2026, 02:28:17 PM »
I’ve had a Dyna ignition system running in my Cb550 k3 with no problems for 12months+ (in fact it’s a massive improvement over points). 

I had to replace my coils six months ago and bought a generic aftermarket set.  Ran perfectly until the last 2 weeks.
If the coils were the wrong resistance, or the Dyna causing too much load for the charging system, why was everything good until 2 weeks ago?
You have a problem with your charging system. ;)
Don't fix it if it ain't broke!
Helmets save brains. Always wear one and ride like everyone is trying to kill you....

Offline 1977_cb550k

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Re: Coil issue
« Reply #18 on: Today at 12:36:58 AM »
You’re right Brains Trust! Just did some testing. 

12.79 V at idle
12.78 V at 4–5k rpm
Coil resistance is 3.7 ohms.

So essentially no charging, and the coils are sucking power big time.

I’m guessing alternator brushes are the likely culprit, but open to any suggestions?

P.s anyone interested in the Bluetooth battery monitor you can find them here:
https://www.quicklynks.com/pro_show.php?id=159 ( I have no affiliation with them)
1977 CB550k3

Offline M 750K6

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Re: Coil issue
« Reply #19 on: Today at 02:08:59 AM »
Befpre changing stuff, check continuity along the charging circuit. Follow your wiring for kinks, burns and clean all plugs/bullets in the charging circuit. Might be lucky.