PVL announced at the Kart Fair in January 2003 that an innovation in generators would be coming onto the market and a prototype was already undergoing trials. Here is the first technical info on the new System 650.
For many drivers it has not been possible to use PVL ignitions until now because e.g. power is urgently required for a 24-hour moped race and previous systems do not have a generator. It is essential to be able to offer a power generation system particularly for retrofitting oldtimer two-wheelers.
We know from our clientele that there is great interest in a digital ignition system with power and we can see a requirement from those who wish to have access to a product such as the System 650 because of a faulty original ignition.
When ordering it should be ensured that the customer (tuner) also orders
the required ignition curve. A maximum of 2 different ignition curves
can be programmed i. e. the programming package price must be added each
time to the system price per ignition curve. The ignition curves can be
drawn on millimetre paper with 16 points so that the programmer has the
necessary curve support points. Should standard curves be used, the required
ignition curves e. g. 479 100 or 105
458 must also be ordered. In any case, the data must be provided by
the purchaser as we must receive accurate data.
The programming unit is used for programming or deletion of the ignition curves. It consists of "Pandora" software on CD, interface 589 200, a power pack and two adaptor cables. The most important part of this programming unit is the interface, without which it is not possible to programme the CDI unit.
- Motorbike/ motorcycle
- Digital ignition system
- Signal for tachometer
- Two ignition timing curves can be selected in operation
- Electronic ignition adjustment is possible during operation (+/- 5°)
- Ignition timing curves can be programmed
- Programmable speed limiter
- Direction of rotation clockwise and anticlockwise
- For single and two-cylinder engines
- Compatible with standard kart ignition system
||< 100 rpm
||> 50 W
||Programmable up to
||Integrated in the stator
||approx. 0.5 kg
||Approx. 615 kg mm²
The components for the PVL Ignition System 650 are listed below. Please order without an official order form byE-Mail quoting the dokutec number.
PVL Ignition 650 with 50 W generator, comprising stator, rotor, E-Box, ignition coil with programming system
dokutec No. 129249
Price including VAT: 1,450.00 Euros
PVL Ignition 650 with 50 W generator, comprising stator, rotor, E-Box, ignition coil without programming system
dokutec No. 129250
Price including VAT: 525.00 Euros
Programming package price for PVL System 650 ignition curve
dokutec No. 129251
Price including VAT: 120.00 Euros
PVL stator 650 800 two-cylinder Ø 94 mm; 650-08.00 IDX D
Note: Similar to illustration
dokutec No. 129596
Price including VAT: 144.50 Euros
PVL rotor 650 940 without cone, 8 mm bore
dokutec No. 129597
Price including VAT: 93.50 Euros
PVL E-Box single-cylinder 650 215 (650-02.15 IDX)
dokutec No. 129598
Price including VAT: 234.50 Euros
PVL cable tree E-Box 650 450, on-board network 8-pole (650-78.00 IDX B)
dokutec No. 129599
Price including VAT: 8.50 Euros
PVL ignition coil 650 100 red (650-01.00 IDX C)
dokutec No. 129600
Price including VAT: 52.50 Euros
Brief operating instructions
To start up the engine the ignition system requires a 12 V external supply voltage which generates the capacitor charge for ignition in the E-Box via a blocking-oscillator circuit. The voltage is supplied to the E-Box by connecting the rt/vio cable to the positive terminal of the battery via a sensor (normally open contact).
Basic Prerequisite: The two earth cables and the negative terminal of the battery must always be connected to the same earth potential (vehicle chassis, engine block etc.) of the vehicle.
During this procedure the E-Box simultaneously switches the yellow cable to the earth potential. A relay can thereby be triggered to switch a starter.
It should be noted that this switching step is only specified for a maximum continuous current of 200 mA.
Important: If you start up your engine without an E-Starter, you will require 12 V on the rt/vio cable for the power supply to the electronics.
From a speed of approx. 350 rpm, the ignition (static ignition timing start) is active and the full ignition power is available.
Normal operation upon start-up
The ignition electronics can be operated without an external 12-V supply from approx. 900 rpm. The internal operating voltage and the ignition capacitor charging voltage are then generated from the charging coil on the stator.
The ignition system has two freely programmable ignition timing curves. Two curves are programmed by PVL whereby the progression of the second curve is offset by 5° later parallel to the first curve (See ignition timing curve).
The electronics now run through the first timing curve depending on the speed. The grey cable must be connected to the earth potential to switch to the second curve. This can be achieved by a mechanical or temperature-dependent switch (engine temperature etc.).
If the earth potential is removed from the grey cable, the ignition system does not jump immediately to Curve 1. A "back-at-speed" is freely programmable. If this speed is not reached, the E-Box continues with the ignition in accordance with the first curve. In order to switch directly and independently of the speed from Curve 2 to Curve 1, a back-at-speed must be selected, which corresponds to the final speed (last support point) of Curve 2.
The ignition timing can be adjusted during operation of the engine by connecting the adjustment unit. The ignition timing can be adjusted +/- 5° by actuating the buttons on the adjustment unit. The value can be stored in the E-Box by triggering the cut-out switch. When the engine is started again, the ignition system now follows the adjusted curve. The adjustment affects Curve 1 and Curve 2 simultaneously. The adjustment affects every point on the curve This means a parallel offset of the total ignition timing curve on the Y axis.
This electronic adjustment shall be equated with the previously standard mechanical ignition timing adjustment by turning the stator plate with fitted contact breaker point.
When the engine is running, a High-Low square signal with an amplitude of 12 V is on the brown cable.
With single-cylinder ignition system: The signal switches the High and Low states once per rotor revolution.
With two-cylinder ignition system: The signal switches the High and Low states twice (180°) per rotor revolution.
In order to stop the engine, the black and yellow cable must touch the earth potential. From this moment, the E-Box no longer emits any ignition pulses.
Programmable switching output
A switching output is available with open collector stage (purple wire), which is used to switch on a relay or a warning light etc. from a selectable speed to be programmed. The switching output is active (on) as long as the current engine speed is greater than the programmed speed (switching hysteresis 100 rpm).
It shall be noted that this switching step is only specified for a maximum continuous current of 200 mA.
The stator is fitted with a generator coil which can supply a power of approx. 70 to 80 W at 12 V into the on-board network via the regulator integrated in the stator baseplate in order to supply the carried consumers with power and to re-charge the carried starter battery for the E-start.
The regulator is fitted internally with a current limiter for an effective output current of approx. 6.5 A. Greater consumers switched on in the on-board network cause a negative charge situation in the battery.
In principle, the generator is only capable of operating with a connected 12 V battery. Should a small light battery with relatively low capacity be carried, full-load NC accumulators must be provided.
NC powerpacks 12 V / 1700 mAh were used without any problems during testing of the ignition system. Operation with E-Start (starter) may necessitate a higher battery capacity.
Ignition system wiring diagram
The specifications on the electrical wiring diagram supplied shall be followed for the installation of the ignition system and its operation. Ensure correct connection of the coloured wires and a secure earth connection!
If any wires on the 8-pole cable tree supplied are not connected for the external e-box wiring or the corresponding function is not used, these wires shall be shortened and their ends insulated.
Single-cylinder wiring diagram
Two-cylinder wiring diagram
Stator single-cylinder Ø 90 mm 650 701
Stator single-cylinder Ø 94 mm 650 700
Stator two-cylinder Ø 90 mm 650 703
Stator two-cylinder Ø 94 mm 650 702
Rotor 650 900
Generator single-cylinder 650 501
E-Box single-cylinder 650 2xx
E-Box two-cylinder 650 3xx
PVL System 650 dimensions