1985 GS550ES Igniter dead, advice needed please!

[victorgallas]

So I just wanted to revive this a little bit.
I have been away from doing too much work on the bike itself but she is getting ready to go for rides soon!

As for as the transistor unit goes. I will be posting a write up with pictures once I dig into the unit that Spyug is sending me to take apart. I fixed my unit, but I did it late at night to get the bike to work and so I didnt take any pics. sorry

But here are some points about it in the meantime that anyone can look up.
When taking the unit apart, the epoxy material used can be broken apart carfully by using small picks and such. I have heard that using acetone sometimes breaks down the epoxy, its a matter of trying out different options. If trying to just chip away the old epoxy, just do it slowly and carefully but its possible to break it apart.


The parts I replaced on mine to revived are the two main transistors at the final stage or the unit, they are located under a black bar that works as a heat sink. I used transistors from radio shack that didnt have the correct values I found online that other people suggested, however initially the transistors would get really hot, now they are getting to a normal temperature and seem to be holding up really good. The bike is running great, I put a set of dyna coils and so far the transistors have been alright.

The links I would suggest people to look are these.
And like I said, i will be posting a work procedure on this, will be in a week or more. I first have to get the transistor unit in the mail from Spyug.

http://www.jetav8r.com/Vision/IgnitionFaq.pdf

[Matchless]

Excellent job! When you get the one from Spyug, please post some pictures of where to open it up and get to the transistors.

I have used 2SD799 transistors as replacements in other ignitors and the GS1000, they also work well. Which did you use?

Thanks for the feedback.

Edit: Sorry forgot you used 2SD1113's. The 2SD799's are available on ebay as well.

[victorgallas]

Hey

I used a transistor from Radio shack, dont have in front of me to tell you the number. But i also read on some forums to use darlington type transistors TIP150. I tried them but they where not working properly when trying to crank and check for spark. So I realized that the TIP150 specs where essentially too high for the application, so I went back to the radio shack ones. Now its been been working great and they havent even been getting soo hot.

But as far as I learned, any NPN Dralington Type transistor with a TO-220 packaging type should work, you may have to play with different specs to make it work with the coils that the bike has. If you have stock coils that are supposed to be about 4.5K primary resistance, you would want a transistor that is close to the 2SD113 transistor. But if you have coils with lower primary resistance you may need transistors with a much higher power capacity.

Of course this has been a learning curve for me as well so I will be keeping updates.
When I get the unit from Spyug, my goal is to complete take a part the unit to list all of the components used so that anyone can just buy these components and rebuild their units.

Excellent job! When you get the one from Spyug, please post some pictures of where to open it up and get to the transistors.

I have used 2SD799 transistors as replacements in other ignitors and the GS1000, they also work well. Which did you use?

Thanks for the feedback.

Edit: Sorry forgot you used 2SD1113's. The 2SD799's are available on ebay as well.

[Matchless]

When I get the unit from Spyug, my goal is to complete take a part the unit to list all of the components used so that anyone can just buy these components and rebuild their units.

That will be very interesting to see the full schematic and parts used. Please keep us informed of your progress on this.
Thanks

[JEEPRUSTY]

The link for the instructions lists yours as one of the models that it will fit. Take a look kit DDK3-2. Dynatek's # is 626-963-1669 I would call them and ask them.

http://www.dynaonline.com/skins/down...-5_2-1_3-2.pdf

So this really fits my 550 without sognifigant mods.
The pdf says so but none of the main web page links indicate that.

I suppose I could make the call. Its cheaper than a new oem unit and me learning to solder my old ignitor is iffy at best.

[victorgallas]

I called the Z1 enterprises guys and I spoke with one of them for about 45 mins about usind the Dyna 2000 system however there would be some modifications needed. This is why they dont have it listed on their site.

What i concluded together with the Z1 guys is that in order to make the dyna 2000 work, the Rotor and pick up plate that goes on the egine would have to be slightly modified to fit the application.

I was willing to do this, since I have access to a CNC mill, manual lathe and a water jet machine, so I was going to fabricate the necessary pieces and publish drawings of the modifications. But since I was able to repair my original CDI box, I didnt look more into this.

But it is a possible solution to use the Dyna2000.

So this really fits my 550 without sognifigant mods.
The pdf says so but none of the main web page links indicate that.

I suppose I could make the call. Its cheaper than a new oem unit and me learning to solder my old ignitor is iffy at best.

[victorgallas]

I will.
Spyug mailed me his CDI which I will be using to do this restoration process.
My goal for his unit is to dissect it completely and keep track of what I had to do since I know many of us out here can use any help to fix these units.

Because I am taking a lot of summer classes, it will be a rather slow process, but I have been working on my bike and this as I can.

Thanks a bunch guys.

That will be very interesting to see the full schematic and parts used. Please keep us informed of your progress on this.
Thanks

[Matchless]

Victor,
Thanks, take your time, there is no rush from my side, its just very good information to have if ever needed.
As per Murphy's Law, if you have a spare igniter you will never need it!
Keep well!

[JEEPRUSTY]

Well I am in denial but I have to conclude that I have two dead igniters.
The pickup coils spec out fine and the resistance tests per the manual for the ignitor point to death.

So here I am with a huge pile of scrap metal awaiting a miracle.
I thought I was immune to electrical problems.

Did the igniter that Spyug sent you come from an 83-86 550?

I know that you are busy but can you elaborate on the work that would need to be done to fit a Dyna 2000?

Or barring that wanna fix my dead igniter?

[victorgallas]

Since i dont have a dyna2000 i havent done any of the modifications needed. But what i was able to ndetermine talking to the guys from z1
is that becuase these bikes have a smaller housing for the pickups th dyna would require you to make a custom maunting plate for te pickup coils and then machine the back of the rotor so that it sits lower. If i purchase a dyna 2000 i will let everyone.know the mods

Well I am in denial but I have to conclude that I have two dead igniters.
The pickup coils spec out fine and the resistance tests per the manual for the ignitor point to death.

So here I am with a huge pile of scrap metal awaiting a miracle.
I thought I was immune to electrical problems.

Did the igniter that Spyug sent you come from an 83-86 550?

I know that you are busy but can you elaborate on the work that would need to be done to fit a Dyna 2000?

Or barring that wanna fix my dead igniter?

[82kat]

Just take the plunge and buy the Dyna ignition. I got mine in the mail today and I should be riding this weekend....

[mike_of_bbg]

Just take the plunge and buy the Dyna ignition. I got mine in the mail today and I should be riding this weekend....

Judging by your user name you have an 82 GS and therefore probably got the Dyna S. You can do that if your bike has mechanical advance. His does not. Add to that he would have to fabricate the backing plate for the much more expensive Dyna 2k to work on his bike.

Here's a tip for you though - check the spacer in the package. Dyna has been shipping too thick a spacer and the mech advance won't work with the spacer in and the crank bolt tightened down. I sanded down the top of my rotor, or you can find a thinner washer (14mm IIRC) to be a thinner spacer. Just so the rotor isn't stuck from advancing and can't come off the advance unit.

[JEEPRUSTY]

Judging by your user name you have an 82 GS and therefore probably got the Dyna S. You can do that if your bike has mechanical advance. His does not. Add to that he would have to fabricate the backing plate for the much more expensive Dyna 2k to work on his bike.

Here's a tip for you though - check the spacer in the package. Dyna has been shipping too thick a spacer and the mech advance won't work with the spacer in and the crank bolt tightened down. I sanded down the top of my rotor, or you can find a thinner washer (14mm IIRC) to be a thinner spacer. Just so the rotor isn't stuck from advancing and can't come off the advance unit.

Well I am going to have to stop grasping at straws. I just pushed the damned bike a half a mile in the heat cos I thought hey its running again lets test it.

Well electronics do like to toy with you don't they!

Are you telling me I can fab a plate to accomodate the dyna 2000?
Hell that can't be too hard and I can co-opt a machinist if need be. Or a blacksmith with a bastard file and malevolent fire pit.

I can whip out my trusty 20 dollar calipers and take measurements of the current timing apparatus.

I may actually cry what with a dead bike and flamingchainsaws stepping out with a hot chick and all.

[mike_of_bbg]

That's what victorgallas's last post said. You might want to contact the fine folks at Z1 Enterprises (who gave him that info) and see if they can shed any light on it for you. If it's just pickups on the plate you may be able to adapt your existing sig gen back plate.

[spyug]

Did the igniter that Spyug sent you come from an 83-86 550?

Jeep, its from an 83 550. I'm hoping Victor can resucitate it as that would be the best case solution I think for most folks. My 750 interchange is likely the next cheapest fix but it too requires some fabricating. Mind you if you're half ways handy, its not a big job even with hand tools. Access to machine tools would be the kat's azz but might even be overkill.

Let's keep our collective finger's crossed for Victor.

Cheers,
Spyug