'81 GS550T ignition replica for a few euro !

[kokar]

http://www.alpha-sports.com/suzuki_parts.htm
part number --> 32900-47320
USD Price 561.79$ is too much !

I decided to find a way to remove the resin and copy the circuit

The removal was done with heat gun and a small screwdriver

at this point I took the parts out, and measure the value of them

[FONT=&quot]

[/FONT]

 

[kokar]

after that i cleaned the PCB

[FONT=&quot]

[/FONT][FONT=&quot]

[/FONT][FONT=&quot]

and here is the new PCB with 2 modification

[/FONT][FONT=&quot]

[/FONT]

 

[kokar]

i gave the pcb with the schematic for develop, so in a few days it will be ready.
In the meantime I collect all the materials to build a simulator to test the ignition when ready

-----> cable from pc power supply

-----> parts

-----> igniter connector

---> deskjet motor

Laser 4050 roller

---> signal generator output

---> SG + roller - magnet

-----> SG + roller - magnet 2

----> SG + roller -magnet 3

---> SG closeup

 

[kokar]

----> cable color

----> SG + motor

---> SG + motor 2

---> test bed

---> spark plugs

as we can see the pickup coil must be between 60 - 80 OHm

signal generator service manual

to be continued ....

 

[Guest]

That's impressive work Kokar! You have far more patience than I do and a few more resources too by the looks...

Will be staying tuned for more updates, and this circuit should work for all the bikes using the same ignitor...

 

[Adler]

Awesome! I love it! You are one innovative guy, I have no doubt we will have a VERY cheap ignitor replacement out of all this!

 

[kokar]

less than 10 euros

 

[Stahlgrau333]

Can't wait to see more!!

What are the modifications that you've made to the board?

 

[kokar]

@Stahlgrau333
as you can see in the original pcb the cable was solder to the copper side of pcb

 

[kokar]

side by side

 

[Nessism]

Extremely impressive work kokar! Hope you hang around GSR after you finish your project. We need more guys like you here!!!

 

[HatchA74]

less than 10 euros

Including getting the PCB created?

 

[kokar]

@HatchA74
Yes , if you made the PCB by yourself
I will provide all the information I have including the part list

look the following link
http://www.custompcb.com/

 

[Nessism]

Circuit looks pretty simple. Could a breadboard be used instead of making a PCB?

 

[Guest]

Kokar I don't think it will make a difference for your testing, but the stock rotor actually has two magnets on it. The second magnet (in direction of rotation) is reverse polarity to the first one and seems to be weaker also. That's just more FYI than anything.

That modification is great! I didn't get enough of the potting off mine to see where the wires terminate, but having them grouped together like you've done is a much better idea.

Ed, a circuit that detailed is possible on a breadboard but it would end up quite a bit larger than that and would require lots of little jumper wires and so forth. It would be very fiddly I would think. I think you'd have to spend a significant amount of time planning it properly to get it to a reasonable size. Certainly possible though

And yeah, this is gonna leave my ignitor thread for dead! Haha

 

[kokar]

Pete, I think that there is one magnet, the other is for counterbalance
In my case I don't have a counterbalance the simulation motor has a lot of vibration

 

[BassCliff]

Hi,

Yes, very nice work. Thanks for sharing!

This article by Mr. Matchless might also be of interest to you.

Repair and Fault finding GS1000G Ignitor.pdf


Thank you for your indulgence,

BassCliff

 

[kokar]

Hi,

Yes, very nice work. Thanks for sharing!

This article by Mr. Matchless might also be of interest to you.

Repair and Fault finding GS1000G Ignitor.pdf


Thank you for your indulgence,

BassCliff

the basic difference is the way that the signal generation is connected with the igniter
the GS1000G has 2 cable , the GS550T has 3 cable

 

[Guest]

Pete, I think that there is one magnet, the other is for counterbalance
In my case I don't have a counterbalance the simulation motor has a lot of vibration

Aaah yes, that's true, however I was referring to there being two magnets on the same face, you can just make them out in the pic below where I'm comparing it with the Dynatek (two vertical lines on the left):

I don't think that will change how you're testing though.

Keep up the good work and keep us up to date with your progress

 

[kokar]

Today I had little progress .....

Tomorrow i will test it with the tester