ZR550 Ignitor Info Request

[Corey]

Kawasaki.com lists a part number for the 90-91 ZR550 Ignitor, and a different one for the 92-93.
‘90-'91 = 21119-1277
'92-'93 = 21119-1313
They both use the same ignition pick up and rotor. The main harness has this same year split part number difference.

Does anyone know the difference in the two Ignitors? Are they interchangeable? Looking to convert my 85 GPz550 ignition to ZR550 Ignition, like a friend of mine has, for better timing advance.

Thank you in advance.

[DaftRusty]

After comparing the US Kawasaki FSM and UK Haynes electrical diagrams and looking through the Kawasaki parts diagrams.....I believe the 92-93 ignitor (part# 21119-1313) is used with the "european" style instruments. (for those that may not know, the US and Canadian model zr550's have totally different gauges and handlebar switches from the rest of the overseas market.)
The parts diagrams on Partzilla only show the chrome bullet style gauges in KPH only for the 92-93 models. And all the electrical diagrams using those gauges use a vastly different electrical layout between the lighting system, handlebar switch gear and the ignitor. The differences between the ability to turn the headlight on and off at will (not allowed in US) coupled with totally different instrument panel creates a totally different electrical harness and ignitor.
Frankly I have yet to see a 92 or 93 zr550 for sale in the US and NEVER any with the chrome bullet style instruments, so as long as you buy any ignitor and harness from the US market and use a US wiring diagram to integrate it into your gpz, you should be fine.

[Corey]

Thank you! I was thinking it had to be something like that. You get an "A+" on your research assignment.

[DaftRusty]

The more I think about it, technically it dosen't matter if the ignitor comes from the UK, Germany or the US. It only matters that you have the matching wiring harness connectors (with some wires to provide the proper pin-out as the manuals don't show what wires go in what terminal on the ignitor) and wiring diagram to go with it. You will more than likely just splice the Zephyr ignitor and ignition pickup into your gpz wiring. It's not like you are re-wiring the whole bike with the Zephyr harness, so it dosen't matter what gauges, switch gear or headlight options the bike it came off had, just simply that you are using the correct connector pin-outs and wiring diagram to decode it all.
They most import bit is that you have the proper zr550 timing rotor, as that is what actually gives you the 13°BTDC @ 1200rpm's and 36°BTDC @ 7000rpm's. The ignitor just has a timing map that uses a formula to advance the timing so many degrees at a certain rpm. The timing rotor (also known as a crank position sensor) is what tells the ignitor what cylinder is in what position and how fast the engine is turning. Thankfully the zr550 timing rotor bolts right up to the gpz550 crank as they are identical. (I know you are aware of all this Corey, but I wanted to describe it for the rest of us who may be hearing it for the first time)
I am actually using a zr550 ignitor with a Zephyr zr750 timing rotor on a 1981 kz750 motor so I know you can adjust the timing by swapping rotors or by slotting the rotor keyway. (The zr750 timing is 12.5°@ idle and 35°@ full advance in case anyone was wondering)

[Corey]

I am all about adding more information to those that might be interested.

Funny you should mention the ZR750, as I am planning on using the ZR750 Rotor with the 12.5* advance, as it is close enough that it won't matter.
90-91 Igniter
ZR550 Pick up
ZR750 Rotor (91-93 US Models)

[DaftRusty]

You are all set! Let us know how it goes.
If you ever get to the point you want to modify the keyway to adjust the timing more, let me know. I have an already modified zr550 rotor that you can play with.

[Corey]

My friend in Florida is using the ZR550 Rotor, 90-91 Igniter and he likes it better than the stock ZX550 Ignition. His bike('84 GPz550) has High Compression 615cc, Web Camshafts' #189 Grind, and CV32 Carbs with ZR550 Intakes. Same carbs I am running on my '85 GPz550. I plan on running this same ZR550 ignition when I rebuild 615cc, Megacycle #478-60 Grind Engine.

Thanks for the help and information.

[Corey]

Here is an update from a friend using the ZR550 Ignition, and testing the ZR750 Rotor on his 12:1 Compression 615cc ZX550 (1984) with Web Cam 410 lift, Grind #189, very similar to megacycle 478-60 grind.
http://www.webcamshafts.com/pages/motor ... 00153.html


This information can also be found on the GPz550 Forum:

http://www.nwsca.com/scripts/gpz_forum_ ... D=9053#top


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Back with an update and additional information for running the ZR 550 ignitor, rotor, and pickup coil

Base timing: 13 deg

Advance curve: +23 deg all-in by 7000 rpm.

Total Advance: 36 deg.


FYI the ZR750 rotor is almost identical to the 550 rotor and bolts right on the end of the crankshaft. I was curious to find out if it could be used on the 550 so, as a test, I bolted one on ran the bike. Results were not positive. The ZR750 trigger wheel is advanced 9 deg relative to the ZR550 so while the bike starts and runs, there's too much advance.

The timing, as fitted to the 550 crank and using the zr550 ignitor:

Base timing: 22 deg
Total timing: 45 deg all in at 7000 rpm
The 750 rotor adds +9 deg of advance at every point in the curve.

The 22 deg of base timing made my bike a little harder to start but it idled faster and was notably stronger from 2k -4k. After 4k there was no improvement and ultimately, it lost power. My engine is 12:1 compression and does not make best power with that much advance. It did not ping but it definitely made less power up top with the added advance. A stock engine may be OK. The stock ZX ignition has total timing of 40/41 deg which is only 4/5 deg less than this test.

The ZR750 rotor is actually Corey's and I believe he will be testing it on his stock 550 engine as well.

Here is an image of both 550 and 750 rotors. 550 above the 750.
https://photos.app.goo.gl/ONjayh3igovT7aKq2

These rotors are flipped over so the "key" slots are visible. When the 550 motor is at TDC, the key slots face straight up like shown in the picture. You can see the position of the trigger points on the rotors relative to the key slots are different.
NOTE: The rotors are flipped over in the picture. As shown, the would be rotating counterclockwise. The tabs on the lower rotor (750) will trigger the pickup coil sooner than the 550.

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Corey

[Richard]

adding as picture (so we don't loose them later)

[Corey]

Thank you for attaching the picture Richard.

Different than that of my 1984-1986 GPz550(ZX550) ignition that has one trigger pointer on the rotor, and 2 pick ups, running a "wasted spark" ignition, firing every 360* of crank revolution, I see the ZR Rotor pictured above, has 4 trigger points on the rotor, and uses only one ignition pick up. Could someone clear this up for me and explain how the ignition on the ZR works? Does the Kawasaki Factory ZR550 Manual explain this?