the igniter unit.

[johnD]

Hi all.
New to the forum as just purchased a really nice Kat 400. Love the way it miniaturises the original, always wanted one.
So, to the topic. I note that the 'igniter' unit seems to be an Achilles heel of these and other related Suzukis of this era. Please feel free to correct any of my points.
From my investigations, it appears to be a TCI type, transistor capacitor ignition and this has poor to no spike protection. Also, old age can cause failures, mainly of capacitors.
I am familiar with these problems, many 80's Yamaha's suffer the same problems.
First. Has anybody upgraded to the far more reliable CDI capacitor discharge ignition type of ECU?
I know that this will require replacement of the ignition coils, but my thoughts are towards a later Bandit unit, (cheap as and readily available).
I know electrics are not the favourite of topics, but I have an electronics background and this is a very simple ignition / safety interlocks unit. Unless there is a very good reason why not, it is something I will be investigating or..... Am I wasting my time and worrying over nothing?

Cheers
JohnD

[fossie]

Just seen this topic , so sorry for late reply .

However I did over 100.000 on a 400 Kat dispatching it and the black box was never an issue for me ...however it had problems with the harness to starter button being crimped by headstock...the symptom were similar . ( engine wise it was sweet , everything wore out in the brakes and carbs )

Now I have had a 250, twice , both times it was the black box failing ...a cheap Chinese replacement solved the problem.
As it does with 400's not in constant use ...so maybe spiking as the charge rates would be higher on a flatter battery ...I know jump starting from a larger battery will not have good results .

Go ahead and let us know your results please .
.( ps I did not understand a word about Cdi / Ecu Hence black box!)

[Tonykat]

I had a failed unit on my 400, got one from aliexpress and it works, happy days.
Tony

[Smallkat]

I also got my igniter from Aliexpress. Bike works fine now.

As you have an electronics background, it would be interesting to see if you can upgrade the ignition system. Uncle Bob is going to take a failed igniter apart and see if it is repairable.

If you do get a Chinese igniter, note that the 400 has a 10,500 rpm rev limiter. Aparently the 250 igniter will fit, which has a 14,000+ rpm rev limit. You just have to remember not to go that far!

[Uncle Bob]

Same here, the AliExpress ignitor has fixed, the gradually getting harder to start, starting issue.

A couple of weeks ago I started it up and it did do a loud backfire before starting, which it had never done with the original one on, but other than that it's been fine. Does it have a 10500rpm limiter? I'll have to test that...

I do have SmallKat's old ignitor (and mine now) to have a look at over the winter. The hardest part seem to be getting into it without really killing the casing, from my first impressions... I was going to replace the electrolytic capacitors (which do fail with age) and probably the transistors.

Be interested if you do get something even more modern working as well...

UB

[johnD]

Looks like I was anticipating things. This has come with an aftermrket ignitor as shown in various other posts. I have cut the mounting lugs off to fit into the tray.
I'll close this post for now as I have other issues, see my next post. (I can see you all shaking your heads already).

[fossie]

I see you have closed this post but for interest , have you a photo of this bike, ...it's not J 437 TBA is it?

[johnD]

Hi Fossie.
No, this one is known to Smallcat, came from a guy up in Scotland whose had ongoing problems, as it would appear have I now......

[Smallkat]

It's Bill's (william.sn032).

We agreed a price to buy but couldn't come to an agreement on payment/delivery.