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GS500 electronic ignition into GS400/425?

Chuck78

Forum Sage
Past Site Supporter
I haven't found any info from searching, but I was curious if a late model GS500 electronic ignition would swap into a GS400/425 crankcase?
I have read that although it is not a listed fitment, the Dyna s for the 400/425 will work on a GS 450 1980 - 1983 with the mechanical advancer assembly, although a spacer may be needed somewhere?
I believe the GS500 and GS450 use virtually the same cases, although I'm scratching my head now trying to remember if they use the exact part number or if the engine mounting is slightly different. I know the crankshafts are identical as well as most of the bottom and accept the shift drum due to the rear sets on the 500 requiring a reverse shift drum.


I'm wondering if the electronic advance version can be easily adapted to the 400/425, so I can get away from using Dyna S ignitions. I just replaced another Dyna S on my GS750 due to coils being out of spec and the center magnet piece getting very sloppy from 50,000 miles of use without pulling off to oil it as instructions describe to install it with a light coating of engine oil. This time I used moly based chassis grease on the replacement. The magnet was rubbing the pickup coils due to it's sloppy worn fit, and wore some of the plastic off, so I swapped it all out for new before a big road trip on the GS750 a few weeks ago.
I've had several other Dyna-S electronic ignition modules fail in the past. They seem to be very delicate as far as voltage supply and heat. I'm just looking to get something a bit more reliable.

I was looking at using the mechanical advancer ignition setup on my 4 cylinders off of a 1980 - 1983 GS just for the pickup section, and then making a DIY GM HEI igniter system based on some schematics and write-ups I had seen a decade or more ago on here. This might be a winter project for next winter to avoid using the Dyna and having failures in the future. The Dyna 2000 does look quite nice but is a little more high-tech and probably more bulky than I would care for.

C5 Optical Trigger ignitions no longer seem to be available for the GS400/425, I had that in my mind but I went to look it up just recently and their website no longer shows any bike ignitions.
 
I heard back from C5 Optical Trigger ignitions, who previously had GS400/425 & GS 4-cylinder ignitions available. I wrote:

Do you still offer the optical trigger ignitions for Suzuki GS motorcycles?
I'd really like to find a good alternative to the Dyna-S ignitions, which occasionally seem to have module failures after several years of regular use.

Thank you,


Their reply:


We stopped using PowerArc ignitions about six years ago, and they are no longer in business.

Our new website is www.c5performs.com

Paul
 
i know it's been a while, but yes, the gs500 stuff will work on a gs400, i have fitted a 2000 gs500 ignition system on my 1983 canadian model gs400, bolt on. easier to find parts.
Marc
 
i know it's been a while, but yes, the gs500 stuff will work on a gs400, i have fitted a 2000 gs500 ignition system on my 1983 canadian model gs400, bolt on. easier to find parts.
Marc

Sorry for the thread hijack, but have you got any more details on the GS500 swap? Did you have to graft the GS500 connectors onto the GS450 harness or do they use generic plugs/sockets that you can buy easily? I may need to do this on my 82 GS450.
 
Sorry for the thread hijack, but have you got any more details on the GS500 swap? Did you have to graft the GS500 connectors onto the GS450 harness or do they use generic plugs/sockets that you can buy easily? I may need to do this on my 82 GS450.

I used the gs500 wiring, I shoud have wirtten, ignition pick up are bolt on, tey are the same, I done this because I had trouble finding ignition coils for the 400 and I had the gs500 complete electrical system at home. I did not care about originality, more about finding newer parts to keep it running.
 
I used the gs500 wiring, I shoud have wirtten, ignition pick up are bolt on, tey are the same, I done this because I had trouble finding ignition coils for the 400 and I had the gs500 complete electrical system at home. I did not care about originality, more about finding newer parts to keep it running.

Thanks for the clarification!

Unfortunately, I cannot find anything here pre-2008 so am looking to go down the Chynatek Dyna knock off path.

From my research, it should be possible to use the setup from the later GS500s, but the ECU on those has a throttle position sensor amongst other things. I'd assume that means you'd need to run those later carbs as well for it to operate correctly, and that adds a whole level of complexity I just don't feel like messing with, not to mention the additional cost. I run 2001 GS500 carbs on mine and am very happy with them.
 
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