Digital Ignition ZDG3 Fitting instructions for digital ignition ZDG3 for YAMAHA XS650 1. Description 2. Fitting 3. Electrical connection 4. Adjustments 5. General Volker Sachse Lerchenweg 12 D32312 Lübbecke 0049 5741/61188 info@elektronik-sachse.de www.elektronik-sachse.de [german version]
3 Fitting instructions for digital ignition ZDG3 (YAMAHA XS650) 1. Desciption - 2. Fitting - 3. Electrical connection - 4.Adjustment - 5. General The digital ignition ZDG3 consists of the following components: - light-barrier printed circuit board - light disk, driver and the cam shaft - adjustment shaft connector - the ignition box and replaces the original breaker points plate and centrifugal governor. Function: per revolution of the crankshaft starting from TDC, the momentary peripheral speed is determined and by this means, the time up to ignition is calculated. Because the peripheral speed varies substantially during acceleration, this long measurement is selected in order to determine a relatively exact measurement. The following computation of ignition timing is divided into 4 ranges: 1. 0-400 rpm Starting range, ignition always at TDC 2. 400-1000 rpm Idling range, 2 or 7 advanced ignition 3. 1000-6200 rpm Partial load range, the spark advance adjustment occurs here 4. 6200-10000 rpm maximum load range, constant 32-39 advanced ignition, depending on curve selection As opposed to the original ignition system, ignition now takes place at each revolution of the crankshaft, thus also during the exhaust stroke. That is because of the fact that this ignition system is used also in other motorcycle types, where the light barriers are directly mounted at the crankshaft. That has however no influence on the engine run, thereby the adjustment becomes easier. ignition box light disk, shaft connector and driver light barrier PCB Why measure by means of a light-barrier? Because as opposed to magnetic pickups which merely give impulses which vary according to RPM and therefore demand a more complicated computation, light-barriers on the give a static output signal. Because at the XS650 both pistons are going up and down at the same time both sparks for both cylinders must be produced at the same time per revolution. If the engine stops, the ignition current will be switched off after 3 sec. to protect the ignition coils.
Seven ignition curves are available: ignition curves
Fitting instructions for digital ignition ZDG3 (YAMAHA XS650) 1. Description - 2.Fitting - 3. Electrical connection - 4. Adjustment - 5. General Remove the original breaker points plate on the left side and the centrifugal governor plate on the right side, remove also the cams of the advance shaft. The two shafts (cam- and advance shaft) must be coupled directly, because the advance adjustment now will be done by the ignition box. The connection occurs by a special connector which is mounted onto the right cam shaft thread (width across flats 27). The connector becomes additional secured by a set-screw. Now push the advance shaft through the cam shaft and the connector with the pin in the notch and tighten it with a locknut. Cam shaft and advance shaft now are connected firmly. (You could also weld both shafts, but that ist really final.) On the left side the driver is pushed onto the advance shaft and tightend with a locknut. Then fasten the printed circuit board witth the original screws and push the light disk onto the driver so far that the disk is in the center of the light barrier, but don't fasten the set-screws yet.
The fixing of the ignition box takes place e.g. at the underside of the seat or with some foam material (as vibration damper) in the toolbox.
The original ignition coils can be used. For using other coils, following restrictions: Except for coils from a 2-stroke engine and CDI types, nearly all types of new or used ignition coils can be used, which corresponds to the electrical conditions: Technical minimum requirement of the ignition coils: Primary resistance (measured between the connections): 3-8 ohms Secondary resistance (measured between high voltage connection and one of the two different): 4,5-15kOhm.
Fitting instructions for digital ignition ZDG3 (YAMAHA XS650) 1. Describtion - 2. Fitting - 3. Electrical Connections - 4. Adjustments - 5. General The wiring takes place with the provided harness. First remove the fuel tank. Remove the cables to the old contact breakers, also the capacitor plugs must be removed. Now put the brown and violet cable into the plug sockets, the order doesn't matter. The brown cable of one ignition coil is connected to the red cable from the harness, and the plug at the red cable moves into the free plug socket. The box connection takes place as shown in the picture. The earth cable can be attached directly at the battery or frame.
Connection allocation of the system plug 1 ignition coil 1 2 ground (Make sure of a good contact to the frame!!) 3 brown, ground (Pickup) 4 green, light barrier (Pickup) 5 yellow, light barrier (Pickup) 6 white, +5V (Pickup) 7 tachometer output 8 +12V (Supply voltage from the ignition switch) 9 ground 10 ignition coil 2
Fitting instructions for digital ignition ZDG3 (YAMAHA XS650) 1. Describtion - 2. Fitting - 3. Electrical connections - 4. Adjustments - 5. General Attention! Remove the sparking plug cap before adjusting the light disc! First both cylinders must be brought on TDC. Therefore remove the generator cover and bring the TDC markings into coincide. Now rotate the light disk into the position as shown on the picture (Which two cutting does not matter). The position is correct when the LED (yellow circle) toggles. Ensure that the light disk is in the centre of the light-barrier! Now tighten the grub screws evenly and replace the spark plug caps. The bike is ready to start. The switches can be found at the front of the ignition box:
switch adjustment 1-7 curves 1-7 6-7 rotary switch (curve selectionl) curves 1-2, double ignition (Guzzi) 1 dip switch overspeed protection at 7900 rpm (switch down) or at 9800 rpm (switch up) 8-10 no function, test mode 2 rev. counter frequency (switch up >> fout =crankshaft switch down >> fout=camshaft )
Fitting instructions for digital ignition ZDG3 (YAMAHA XS650) 1. Description - 2.Fitting - 3. Electrical connection - 4. Adjustment - 5. General Only use interference-free caps for the spark plugs! (recommended NGK caps with 5kOhm internal resistance) At some stroboscope lamps the ignition point suddenly oscillates around 4-6. In this case the lamp once reacts to the ignition spark starting, another time to the burning end of the spark. If possible readjust the sensitivity of the lamp. Another possibility is to put an 0,1uF/400V-capacitor provisionally during the adjustment over the connections of the respective ignition coil. If the engine should not start with slowly turning starter, probably the battery voltage falls under the minimum supply voltage of the ignition (approx. 7V). In this case charge the battery or check the bonding battery/ framework. Volker Sachse Electronic development and manufacturing Lerchenweg 12 32312 Luebbecke Germany Tel. 0049 5741/61188 Mobil: 0049 160/9414 2224 info@elektronik-sachse.de www.elektronik-sachse.de