Pamco Instructions - Kawasaki KZ650

Before Installing:

1. Make sure you have a good running engine to begin with! You don't want to end up chasing your tail trying to troubleshoot a problem that has nothing to do with the ignition.

2.Admittedly, setting the timing is not the easiest procedure. It requires patience and an understanding that the system is precise and requires some trial and error to get right. Once set correctly, however, it will probably never have to be readjusted. That's the beauty of an electronic ignition!

3. Make sure your battery is fully charged prior to installation.
 
4. Make sure the main switch is off and the battery positive lead is disconnected and secured, before installing.
 
5. Get a good quality timing light if you don't own one already. If it has an advance preset, set it to zero.
 

Installation Instructions:

1. Remove the points plate and advance mechanism.

2. Remove the points cam from the advance mechanism. On some models with the advance mechanism, it is necessary to remove the weights as the points cam has a flange on the bottom.

3. Reinstall the weights if removed in step 2.

4. Apply a light coating of grease on the advancer shaft.

Note: On some advancers there is a small pin located on the shaft of the advancer. If you have this pin on your advancer, follow these instructions:

1. Check for the pin and if there grind off with small grinding tool or file.  If necessary clean with WD-40 to remove metal particles then apply light oil to prevent rust.

2. Apply a light coating of grease on the advancer shaft.

3. Once the rotor is bolted to advancer check for free movement and spring return.
 
The PAMCO rotor is now installed on the advance mechanism with the PAMCO plate in between. Each advance weight must be extended in order for the slots in the PAMCO rotor to engage the small tabs on the weights.
 
1. Place the rotor on a flat surface.

2. Place the PAMCO plate on  the rotor.

3. Hold the weights in the extended position and insert the tabs on the weights into the slots of the PAMCO rotor.

4. The rotor can engage the tabs on the weights in one of two ways. This is the preferred way. (Shown without the plate for clarity)

5. With the trigger magnet positioned as shown above, the green wire from the trigger on the right goes to the coil for cylinders 2 and 3 (green wire), and the other green wire goes to the coil for cylinders 1 and 4 (black wire). If you assemble the rotor with 1-4 in place of 2-3 as shown, then you can either do it again, or just reverse the wires for each cylinder.

6. Install the PAMCO plate and rotor in place of the points plate with the upper mounting screw in the center of its slot.
 
7. There is a subharness that runs to the points, which is removed with the points.  Run a new blue/red wire for the oil pressure switch (found under the points plate).

It's easiest to retain the connection to the kill switch lead , which is yellow with a red stripe. Located to the rear of the coils along the frame backbone. Replace the double female connector on the lead from the kill switch with a triple female. Retain the connection to the coils. Run a lead from the third open female connection which runs to the red wires on the PAMCO. For the ground, there is a convenient single female connector on the common ground wire (black with yellow stripe) near the battery. Replace the single female terminal with a double female, and run a wire from this terminal to the PAMCO black leads.

Alternately, there is a typical rear brake switch with a hot switched wire in a convenient place which can be used to power the PAMCO red wires.
 
8. After you have started the engine, use a timing light connected to cylinder #4 and look in the hole on the top of the plate to see where the timing is.

8. Loosen the mounting screws for the plate and rotate it clockwise to retard the timing or counterclockwise to advance the timing.

9. Set the timing at the "F" mark at 1000 RPM and then check for max advance at 3200 RPM.

10. Secure the mounting screws.

Installation Comments from KZ650 owner Mark Chegwidden (aka, chuckwagon)  who installed the PAMCO:

"The right set of points is for the 2/3 cylinders, and is connected to green on the original loom.  The left set is for 1/4 and is connected to black wire in the loom.  To retain the same left and right order for the pickups on the PAMCO the PAMCO rotor must be installed on the advance mechanism so that the rotor magnets are near the 2/3 mark and the "TEC" brand stamp, not the 1/4 marks.  I find it is easiest to test fit the rotor to the advance to make sure it works.  I then fit the advance to the crank, test fit the rotor to get the positioning figured out.  Then I put the ignition plate on, and fit the rotor in the correct position.  I find that gently pressing the rotor while wiggling it a little with seat it on the advance properly.

There is a keyed 17mm nut that fits to the end of the advance mechanism, then a 13mm bolt that threads into the crank end.  The 17mm nut is to hold the crank steady while the 13mm bolt is tightened or loosened.

To verify that the rotor is positioned properly, when the setup magnet is at approximately 12 o'clock position, the # 2/3 should be visible through the timing sight hole in the ignition plate (not 1/4).  If they get it backward, they will just have to reverse the green wires...same as on the CB750.

As far as wiring, There is a subharness that runs to the points, with I removed.  I had to run a new blue/red wire for my oil pressure switch (found under the points plate).

I found it easiest to retain the connection to the kill switch lead , which is yellow with a red stripe.  Located to the rear of the coils along the frame backbone... I replaced the double female connector on the lead from the kill switch with a triple female.  I then retained the connection to the coils.  I then ran a lead from the third open female connection (yellow wire in the photo), which runs to the red wires on the PAMCO.  For the ground, there is a convenient single female connector on the common ground wire (black with yellow stripe) near the battery.  I replaced the single female terminal with a double female, and ran a wire from this terminal to the PAMCO black leads.

Alternately, there is a typical rear brake switch with a hot switched wire in a convenient place  The brake light "hot" lead is always powered regardless of kill switch setting.

Lastly, the wiring schematic is a little misleading... the sparkplugs are shown so that they look like the left coil powers 1&2, right coil powers 3&4... not so.  Left coil powers 2/3, right powers 1/4 (as viewed from sitting on bike)."

Technical Information:

Hall effect sensor, IGBT coil driver
Dwell: Fixed, 120 degrees
Coil primary resistance: 2.5 to 5.0 Ohms, dual output. (Stock coils or aftermarket may be reused)
Operating voltage: 6 to 18 VDC
Operating current: 13 ma
Operating Temperature: -40 to +150C (-40 to 302F)
Spark Advance: Standard, centrifugal
Plate milled from high quality aluminum.
Rotor with two magnets made from a solid billet of aluminum on a CNC machine.