'81 GS550 No spark after rebuild

[Benreh]

Evening gents.

After rebuilding my engine and getting the bike back in one piece the damn thing has lost its spark!

First things first, All my connections are fine, checked and solid. Stator is fine, not had a chance to check the coils but I can't see both coils going at the same time.

Confirmed power is getting to the coils, I have checked my pickups and they are good.

Running out of things to check and really don't feel like splitting the loom and checking every wire as it sparked fine before i pulled and rebuilt the sucker.

I have been advised it is possibly the CDI box, can anyone advise me how to test this?

 

[tom203]

Since it sparked before your handiwork, must be bad connection somewhere. It's unlikely the ignitor went bad while on break.Head to this link to test ignition system

http://members.dslextreme.com/users/storagecliff/images/electrical_odd-n-ends.html#A17

 

[Benreh]

Wow, that looks massively useful cheers buddy.

Best use some of that stored up holiday time from work.

 

[Benreh]

Ok.

So far not so good.

Followed http://members.dslextreme.com/users/...-ends.html#A17 to the letter and rather sadly it turns out that the offending unit is the ignitor box...

Anyone in the UK with a GS550 I can post it to the plug it in and confirm that its borked?

On the plus side I have pulled the whole harness off and cleaned every single connection so they shine and greased the lot so no nasty crap can get back in there, for a bike of its age its pretty damn solid.

While its apart its also inspired me to take of the mudguards and strip them down for repainting alongside the tank and side panels.
View attachment 37448
This lovely brass work is getting the crap polished out of it and going back on the custom rear mudguard.

 

[tom203]

That's unfortunate.You might be a candidate for a dyna ignition system- this replaces both the ignitor and signal coils . The 550's seem to have lots of ignitor failures and a stock replacement ignitor is absurdly expensive.

 

[Benreh]

Ok, so looking at the Dyna S http://www.ebay.co.uk/itm/Suzuki-GS...pt=UK_Motorcycle_Parts_13&hash=item5407e0f3cc.

So this replaces the whole pickups/ignitor box setup and wires straight into the coils, no muss, no fuss, no weeping softly into the garage wall when it doesn't work?

 

[tom203]

Yes, replaces the stock ignitor and the stock signal coils with one gizmo. As far as weeping goes, sure to find other stuff that needs money/attention!

 

[Benreh]

Cracking, good job I did some saving up then.

If i do have to source new coils are the dyna ones any good?

 

[tom203]

Cracking, good job I did some saving up then.

If i do have to source new coils are the dyna ones any good?

If you got money to burn, the dyna 3 ohm coils get high praise, but the dyna ignition will work fine with stock suzuki coils, so you can wait and get them later if you find nothing else needs your money.
Hopefully you have you noticed all the hype about the SH-775 r/r's on here-

 

[Benreh]

In all honesty I have not been doing much reading due to new job training and I am only just really getting stuck into the bike.

I will do some r/r searching and make some notes.

 

[tom203]

Have a look at this thread, installed a SH-775 to solve charging woes- this is good insurance to protect your bike's electricals and still get good output.

http://www.thegsresources.com/_foru...ng-stock-RR-with-SH-775&p=2134991#post2134991

 

[Benreh]

Brill,

Also in a stroke of luck i managed to find a igniter box for a decent price that will be with my early next week best get the loom back on and hooked up and who know I might be finding other problems come xmas.

 

[Benreh]

Update:

Boom the bugger runs. I have finally got around to getting everything together and despite there being no spark after my first assembly after i had double checked the connections and tested the new ignitor unit with a 1.5v battery got a spark on both coils, jabbed the starter and all 4 were sparking away happily.

On the off chance it would run it put the whole thing back together spun her up and nothing... the spark had gone again...

After much fiddling with switches I stomped off (in a huff) for a cup of tea (its -2 here and i don't have a garage) came back out gave her some choke, squeezed the clutch and jabbed the starter and boom a bit of coughing and finally started.

Left it running for half an hour fiddled with the idle and it was idling at 1.5-2k revs with no airbox and standard jets.

Sounds sweet as a nut, firing fine on all four, now the real work can begin

 

[tom203]

Progress is always good! We will send warmer weather your way.