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1985 GS550ES Igniter dead, advice needed please!

  • Thread starter Thread starter victorgallas
  • Start date Start date
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.



JEEPRUSTY said:
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.
Click to expand...
 
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.


Matchless said:
That will be very interesting to see the full schematic and parts used. Please keep us informed of your progress on this.
Thanks
Click to expand...
 
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!
 
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?
 
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

JEEPRUSTY said:
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?
Click to expand...
 
Just take the plunge and buy the Dyna ignition. I got mine in the mail today and I should be riding this weekend....
 
82kat said:
Just take the plunge and buy the Dyna ignition. I got mine in the mail today and I should be riding this weekend....
Click to expand...

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.
 
mike_of_bbg said:
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.
Click to expand...


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.
 
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.
 
Did the igniter that Spyug sent you come from an 83-86 550?
Click to expand...

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
 
When I called the Z1 guys, they have never tried to install a Dyna 2000 on a bike like ours with transistorized units. But for what he explained to me is that the transistorized bikes have a much smaller ignition pick up housing, thus the possibility of having to modify the rotor and pickup plate.

I don't think it would be a hard job to do. I just ended up not having to do it at the moment, as I was able to make my stock CDI work again for me without any problems so far.

I will admit i am quite interested in getting the Dyna 2000. I may do it on the fall semester once I get some more money.... In the meantime my goal is to just finish the bike and have it running.

JEEPRUSTY said:
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.
Click to expand...
 
Yeah Spyug,

I am hoping you're unit comes in during this coming week and by next weekend I should have some more time to dissect your unit and make a schematic diagram for it and pics of how to fix it.
I am definitely happy with my unit so far. Has been working good so far.

BTW here are pictures of her so far

http://www.facebook.com/media/set/?set=a.10100107022807358.2465484.12710448&l=af9ee65b5c


spyug said:
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
Click to expand...
 
Last edited:
GS 550 83-86 signal gnerator measuring

GS 550 83-86 signal gnerator measuring

I am at a loss. I made some measurements today.
I am no machinist so these may be a bit rough. I did my best with a digital caliper.

Also some of the parts such as the base are die-cut not machined. There is also a bit of corrosion on the parts which is not helping.


Dimensions from cover minimum clearance
from base plate to extent of rotor
28 mm
base plate thicknes is 2.36-2.39 mm
baseplate is 80.0 mm in diameter
centre hole that rotor passes through is 27.4

Rotor
41.14 rotor to extent of tab.
26.6 in dia. The pick up coil plastic bodies almost rub against this the distance is very small and is slighty varied at least when eyeballed.
steps down to 24 mm dia. where it seats
slot in bottom that crank locator pin sit in is 4.03 mm
6.35 6.42 is the depth of the stepped part that seats into the crank.
center hole that bolt goes through is 8.4
18.05 mm of bolt passes beyond base of rotor and theads into the crank.
bolt is 6mm hex53.26 in length 7.92 mm shank
rotor is not magnetic
magnets are under coils on baseplate.

mounting bolt holes for baseplate are 75.27 outside 64.7 inside
the holes for the mounting bolts are are 5.20 mm in diameter I am not really sure how to measure this at all but there are only two holes ( that I can see ) for attaching a base plate.
fiche at Alpha Sports has part numbers for some of the bits.
09125-05024 are the base screws.
08322-01057 is the washer for above screw.
07130-0845B is the hex bolt that secures the rotor.

So if my efforts at measuring can be somehow understood and compared against the dyna 2000 we can see how hard a retrofit would be.

I wish I could plug these into a primitive cad program.
 
Hey,

thanks for taking those measurements. The only thing is that I have yet to see any Dyna 2000 documentation that has actual dimensions on the pickup components. Also their rotor is magnetic and the points are not. So its backwards from the factory setup.

Also, in terms of CAD program, check this list out.
http://www.freecad.com/CAD_Programs_-_Windows/index.asp?page=2

But if all you need is a simple 2d Drawing, Power point or paint can do the job. Sure it will be annoying to do it, but not impossible :)

have you found any dimensional details that the dyna 2000 uses? I havent been able to, thats why i ask.



JEEPRUSTY said:
I am at a loss. I made some measurements today.
I am no machinist so these may be a bit rough. I did my best with a digital caliper.

Also some of the parts such as the base are die-cut not machined. There is also a bit of corrosion on the parts which is not helping.


Dimensions from cover minimum clearance
from base plate to extent of rotor
28 mm
base plate thicknes is 2.36-2.39 mm
baseplate is 80.0 mm in diameter
centre hole that rotor passes through is 27.4

Rotor
41.14 rotor to extent of tab.
26.6 in dia. The pick up coil plastic bodies almost rub against this the distance is very small and is slighty varied at least when eyeballed.
steps down to 24 mm dia. where it seats
slot in bottom that crank locator pin sit in is 4.03 mm
6.35 6.42 is the depth of the stepped part that seats into the crank.
center hole that bolt goes through is 8.4
18.05 mm of bolt passes beyond base of rotor and theads into the crank.
bolt is 6mm hex53.26 in length 7.92 mm shank
rotor is not magnetic
magnets are under coils on baseplate.

mounting bolt holes for baseplate are 75.27 outside 64.7 inside
the holes for the mounting bolts are are 5.20 mm in diameter I am not really sure how to measure this at all but there are only two holes ( that I can see ) for attaching a base plate.
fiche at Alpha Sports has part numbers for some of the bits.
09125-05024 are the base screws.
08322-01057 is the washer for above screw.
07130-0845B is the hex bolt that secures the rotor.

So if my efforts at measuring can be somehow understood and compared against the dyna 2000 we can see how hard a retrofit would be.

I wish I could plug these into a primitive cad program.
Click to expand...
 
I will try to search out other sites to get the dimensions.
Most things I see merely are threads about specific bikes and if they fit them or not.

No one seems to measure except the guy that makes the first successful application. Then this information is never divulged. It is as if they use a rat tail file and spite to do the job.

Anyway Someone must have written it down.
I contacted Dynatek and typical of a large concern they have not ( and likely will not ) reply.

I PMd Jeff Saunders at Z1 and he had some useful information. He even related a story of someone rigging up a modified Dyna S for a 2-strok triple. So this can likely be done. Nice response the guy obviously cares and wants to help. that was refreshing.

Jeff said the mounting plate was large on the Dyna 2000 trigger plate.

I will look and we shall slay this wretched dragon. And the heavens will part and so on and so forth.

One thing you see is references to intolerance for voltage spikes.
I wonder if one of the gurus here could explain how to rig a simple and one time use device that could intercept a spike.
Something like thos computer power bars are supposed to do. This would be nasty in a normal driving situation esp in a curve. But it would be nice to be able to test a new ignition with a layer of protection.
 
Last edited:
In a letter from Dynatek:

"Thank you for your interest in Dynatek ignitions. Unfortunately, we do not
offer an ignition system for this model at this time. As I understand the 83'
engine it uses the newer style engine that has a 2 bolt mounting configuration
for the pickup plate. Both the Dyna S & Dyna 2000 use a 3 bolt arrangement
like the 1100 engine uses. I believe there are dimensional differences in the
rotor mounting as well. If we can be of any further assistance, please feel
free to contact us anytime."

Telling people what they already know is a bit annoying especially in light of my query stating everything that was in the canned response.

I am calling them on Christmas day I swear!
 
Yeah I hate those formatted responses some companies do.
Now more and more I want to make this system work with our bikes. I wish I had the money at the moment to just order a kit.
Their excuse that the pickup plate has three slots and our uses two is the most lame excuse ever. I mean its a simple plate. If all that is necessary is to just design a different style of mounting plate, then hell I can easily desing and cut it using the waterjet machine, so it will be a simple bolt on. May have to modify the rotor.

But I am with you, I think this can be done!



JEEPRUSTY said:
In a letter from Dynatek:

"Thank you for your interest in Dynatek ignitions. Unfortunately, we do not
offer an ignition system for this model at this time. As I understand the 83'
engine it uses the newer style engine that has a 2 bolt mounting configuration
for the pickup plate. Both the Dyna S & Dyna 2000 use a 3 bolt arrangement
like the 1100 engine uses. I believe there are dimensional differences in the
rotor mounting as well. If we can be of any further assistance, please feel
free to contact us anytime."

Telling people what they already know is a bit annoying especially in light of my query stating everything that was in the canned response.

I am calling them on Christmas day I swear!
Click to expand...
 
Hey victor how is the rebuilding process of that ignitor going? I was going to try to rebuild mine after seeing this but im thuroughly confused on wtf to do or even start with lol.
 
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