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82 gs550 igniter replacement

  • Thread starter Thread starter kentanis
  • Start date Start date
K

kentanis

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Hey guys - long time reader, first time writing.

Got an 82 gs550l, cranks, doesn't start. In the beginning this was intermittent but over two weeks of troubleshooting grew worse. The bike no longer runs.

I've ruled out coils (both wouldn't fail intermittently in perfect synchronization), fuses and the wiring harness (the signal generator still gets power when the key is on), and the signal generator (as per a resistance test in my Clymer manual).

Testing the igniter by grounding the #3 and #4 spark plugs and simulating a pulse from the signal generator suggested a failed igniter.

Based on my research here and elsewhere, the 82 gs550 (no points on this one) is a candidate for the Dyna S ignition system. My questions for you gentlemen are as follows:

a) is the problem my igniter or is there something else in the system I should check?

b) is the 82 gs550 in fact a candidate for the Dyna S ignition system?

c) are there differences among Dyna S units? I've seen them marked Honda, Harley, etc... they all look the same

d) though it looks like a signal generator, does the Dyna S in fact replace both my igniter and my signal generator and if so what wiring shennanigans needs to happen to bypass the old igniter hookup?

Thanks for reading - I could not own a bike this badass without your help.
 
Dyna S is applicable for your bike. Check the Dyna website to make sure you get the right model. It replaces both ignitor and signal generators, and works perfectly with your stock coils. Another thing to check is voltage at the coils. Often resistance builds in the harness and the coil voltage drops, which affects spark quality. Fix is to clean the contacts, or perform the coil relay mod (documentation on basscliff's site). http://members.dslextreme.com/users/bikecliff/

Good luck.
 
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Also make sure the ignitor is "seeing" a good 12 volts too! power goes from kill switch to coils and on to ignitor thru connectors- ignitors don't like voltage drops.
 
Checked out the Dyna site: http://www.dynaonline.com/skins/products/sportbikes/dyna_s/

It claims "no dice" for my bike. The DS3-2 looks close but is for the older points-based model. Can I make one of these work?

I'll check power to the coils tomorrow just to be certain - it can't hurt.


The following is pasted from the Dyna site:

  • Suzuki DS3-1 550/750 four cylinder (KD) 1977-1978 $166.99
  • Suzuki DS3-2 550/750/850/1000/1100 Four Cylinder (ND) 1977-1981 $166.99
  • Suzuki DS3-2 1000/1100 1982-1983 $166.99
  • Suzuki DS3-3C GS 400 Twin w/coils 1976-1978 $317.99
 
Check powers and grounds: power to the coils and the ignitor, ground from the the ignitor.

With good power and ground, pull plugs 3+4 or 1+2 from the head and connect all 4 spark plug leads to the plugs, lay the two pulled plugs on the cylinder head ensuring good/clean ground contact and proceed with testing your signal generator by either cranking the engine with the key on and run/stop switch in the run position or by doing the battery test found in the repair/service manual.

If the test fails when cranking but the system works with the battery test then your signal generator is at fault. If the test fails with both methods the ignitor is suspect, assuming (not really assuming, you did test them right?) all powers and grounds are good.
 
I can guarantee the DS3-2 works for your bike. It was originally made for a points ignition but will work just fine to replace the factory electronic ignition on mechanically advanced bikes as well.

Here's one installed on a GS550LZ now ;) :

ds3_installed_001.JPG
 
Mike,
Check your email. I have sent you a document on this.
 
Hey guys! Updating with photos, close but no post-repair cigar.

http://imgur.com/a/3U3df#0
Click here for bigger versions of the photos

The Dyna S came yesterday.
rWiKHkWs.jpg

See the contents in photo 2.
yFNh8Wzs.jpg

Photo 3 is one of Bonnie, my GS.
JggsFIOs.jpg

Photo 4 is Bonnie minus covers and tank.
dgqbu4gs.jpg

Photo 5 is the old signal generator.
Z8vcv7ys.jpg

Photo 6 is the remains of the signal generator minus the sensors.
NkuBfqjs.jpg

Photo 7 is after the installation of the new rotor and sensors.
XfMYGB7s.jpg

Photo 8 is my glorious wiring job - skipping the now-obsolete igniter to send a signal directly to the coils. Forgive the uninsulated spade connectors - they are temporary to facilitate testing.
http://i.imgur.com/3CrZADNs.jpg

Thank you all for your tests, photos, and shopping assistance.

The bad news? The engine still cranks without spark.
@MATCHLESS Do you think the document might be of use to me as well?

A bit more information for y'all:
I've tested resistance of the coils by setting my multimeter to 200 ohms and connecting the leads to the small wires entering the coils from the signal generator. The first time both tested at 2.5 - below spec. I tested them twice more, and each time got ~5. It is my assumption then that the coils themselves are fine.

When I turn on the key and check power to the coils, only one is getting power. My shop manual assures me that this is normal, however, manually advancing the engine by 1/2 a rotation does not switch power to the other coil. Is this normal? Is it a clue?

My suspicion at this time is that the coils share a ground somewhere deep in the wiring harness and that this ground has possibly failed, causing my problems from the beginning. Before moving on to the famed coil relay mod, I wanted to get your input.

Did I miss something obvious?
Are my coils at fault?
Is my coil GROUND the problem? If so, can I just splice a new direct-to-battery ground onto the current lines?

Thanks again for your help up to this point. You guys are always great.
 
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It would be a good idea if you read through that document I sent you!;)

Ok lets look at the basics.

The coils get "power" from a fuse when the ignition switch is on. Test for +12V between the battery ground and the two orange/white wires on each coil and the orange/white connected to the red wire coming from the Dyna

The Dyna gets its ground from the engine frame. The coils get ground pulses from the Dyna.

The Dyna white wire is connected to the white wire from the coil and the black wire to the black/yellow on the other coil. The brown and green/white you have the white and black connected to could be the old pickup colors going to the old ignitor connector, that is what it seems like on the last picture.Check this first.

And that is it. Do the bulb test to see if the pickup is switching as in my document and the Dyna instructions. If it does the pickup is working. Meaning it is getting power and is sending a ground out to the coil. It then needs to actually get to the coil!

You will not get a spark if both plug leads on the same coil are disconnected with only one spark plug fitted, The other spark plug lead on the same coil needs to be grounded by a spark plug as well to complete the secondary circuit.

Hope this helps!
 
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Wow Matchless - that document is amazing! Also, as I think about it, you're right about my wiring. After all that work, I wired the Dyna right back into my old igniter. Hopefully I can patch that up tonight.
 
Fixed. For those who helped me and any future forum-searchers, here's the story:

I wired the new dyna system right back into the old, cooked igniter. Matchless was able to pick out my error from one of my photos. I rewired the dyna... right into the old signal generator wire. That's when I decided to quit drinking! Wired everything up properly with some help from a photo-guide Matchless sent me. Check it out at this link: http://www.mediafire.com/view/iicnca842t47hnx/Suzuki_GS550_Dyna-s_Pictorial.pdf

He supplements the dyna instructions a little, resulting in a more elegant and easy-to-maintain install. The bike started almost immediately. I've missed that sound! No crotch rocket or overpowered cruiser can match it.

I timed the bike, albeit poorly as you'll probably hear below. I'll re-do it later. Time to take my wife to the hospital - my first child is likely going to be born some time tonight!

In closing, to thank you all for your help, I've uploaded a video of Bonnie starting and revving once. For reference, this is a cold start, petcock set to ON, choke off. If the petcock is set to PRIME and the choke on, she starts at the lightest touch of the button but I wanted to show off a little: http://youtu.be/SL7Goi6x2uo
 
how did it go? I am working through a similar problem and this thread has been amazing. But, there is no end to the story.
 
frank_dit said:
how did it go? I am working through a similar problem and this thread has been amazing. But, there is no end to the story.
Click to expand...
It's a four year old thread - been lots and lots of recent posts on ignition issues. What bike do you have and what's the problem?
 
I know this is a five year old thread but that write-up by Matchless is invaluable. Layed out the entire process so much clearer than the included directions so just wanted to say thanks.

I ended up filing down the spacer that came with the kit as predicted. That wasn't the most enjoyable task but knowing i was moving in the right direction definitely helped.
 
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