TS ignition conversion

[tony27]

Finally got round to finishing off fitting the Suzuki ignition to my 73 380 & thought a few photos may be of interest to anyone considering doing the same
A big thank you to Sudman for coming round last weekend with his timing light

http://s788.photobucket.com/albums/yy166/tony27_photo/CZ%20electronic%20ignition%20conversion/

The original marks on the stator plate turned out to be about 120deg out when lined up with the marks on the flywheel, Tony used his memory of owning a TS back in the 70s to work roughly how the coils sat
If people want I can post the photos individually & am happy to give any more details that may help with doing the conversion

[VMX60]

Tony

Please post in detail  your Ts Suzuki  /CZ cdi  Over the last few year everybody I talk to cannot fill in the the fine detail, Last time Drakey came to the West running this cdi the only detail was send your complete Flywheel to Victoria and as far a I know they were replaced by TS185ER model parts

Have also stock piled a  lot of Suzuki parts so if you can supply

flywheel part number
CDI box part number or model
Keyway offset to timing marks

What ever you post will sure help out a lot of CZ guys

Thanks

[tony27]

The bike is assembled ready for a test run at a vmx fun day type meeting on sunday so I don't want to disturb things until next week but I'll give you as much info numberwise as I can
From zooming in on the flywheel pic the details appear to be Kokusan FP4368  has marker saying TS400 but is meant to be close to 185
CDI is also Kokusan 32900-30520  marked as TS185
The coil is off a Yamaha RD400 with the original terminals changed to fit the Suzuki plug, I have a TS185 coil to try at a later date when I get around to repairing/modifying the butchered 74 model head thats sitting on my bench at work. The RD coil is actually narrower than the TS coil even though it has 2 plug leads coming off it
I won't be able to find numbers off the stator due to it being turned down to fit into the CZ cover. I made a spacer for inside the stator plate as the mounting holes end up partway into a step, I used longer screws through original lighting coil etc mounts to hold it in place
I'll take things off next week & take some more detailed photos to explain things better

[VMX60]

Tony

Thanks for the follow up the part numbers alone are a great help to ID early or late er185 model Suzuki

This is to go on to  this summers 360cc sidepiper rebuild so no big hurry when you have time

Tried to blowup your Photobucket pics to small to read the numbers

Cheers

[tony27]

Looks like I'll be able to gets lots of photos this week after the bike did quite a bit of pinking coming back on the throttle out of corners


Going to have to do a full stripdown to remove the particles of piston that have gone everywhere including the inlet port

[foxy999]

thats no good, hope all is well in the bottom end..........

[LWC82PE]

Part # = 32900-30520
Part Description = CDI UNIT
Model Count = 10
DS185C 1978
DS185N 1979
DS185T 1980
DS250T 1980
TS185B 1977
TS185C 1978
TS185N 1979
TS185T 1980
TS185X 1981 
TS250B 1977

PLUS its the same ALL TS185ER 1979 to roughly 2000 or what ever the latest model is. Zedder programe is US only so no ER variants show up in the list. Basically all 185 CDI units from 1977 onwards are the same.

[tony27]

Bottom end feels ok with no vertical play just the normal side to side that 380s have, something sitting in the bottom of the cases which jam the crank at BDC though

[GMC]

Part # = 32900-30520
Part Description = CDI UNIT
Model Count = 10
DS185C 1978
DS185N 1979
DS185T 1980
DS250T 1980
TS185B 1977
TS185C 1978
TS185N 1979
TS185T 1980
TS185X 1981 
TS250B 1977

PLUS its the same ALL TS185ER 1979 to roughly 2000 or what ever the latest model is. Zedder programe is US only so no ER variants show up in the list. Basically all 185 CDI units from 1977 onwards are the same.

What about TS 125?
Did they run the same ignition as the 185's?

[LWC82PE]

No, 125 has points till the monoshock ERZ 82 model which had CDI but it was a totally different set up to the 185.

[Noel]

Hi Tony ,a Question about setting the timing,
did you set to
 CZ statict spec's   or
 TS spec's (21.5 at 6000rpm)

cheers
Noel

[tony27]

Ended up using a timing light so that max advance occured at the same point as the CZ did on points, bike ran really well in the weekend apart from throwing the chain a couple of times.
Bike is much easier to start & even though the flywheel weighs the same as the original it seems to pick up revs quicker, as a bonus it finally idles

[VMX60]

Tony

Thanks again for the Suzuki details

Your last ride confirms its the way to go when the timing is right
And the price is right compared to CDI units sold by the dealers

Cheers

[tony27]

Had a bit of a setback at the third round of the eNZed series in November, bike ran perfectly in practice & the first race but wouldn't restart after the race.
The spark had disappeared & I couldn't find any broken or loose wires
Back at home later in the week I tested the stator resistance which was okay, tried another CDI without luck. I think the lead to the front plug may have broken internally due to the bend to the cap, I changed to a 45deg cap & shortened the wire which gave me spark again
I came across a listing for a new coil to fit GT500/GT250X7s made by Rex's speed shop & bought 1 a few days before new years, was in my hands just after new years day & has the correct connector for the CDI unit & leads double the length needed. I can't rate their service highly enough
I've made up a new mounting bracket to fit & shortened the leads, bike now runs as it should & hopefully it won't miss a beat this weekend for the fourth round of the series


The new coil mounted up with much smoother lines for the plugs leads