User guide

ManualsBrandsS&S Cycle ManualsFor motorcyclesIST Ignition System for 1984-1999 Big Twin and Custom Applications

S&S

Cycle, Inc.

14025 Cty Hwy G PO Box 215

Viola, Wisconsin 54664

  

Technical Service Phone: 608-627-TECH (8324)

Technical Service Email: sstech@sscycle.com

Website: www.sscycle.com

Installation Instructions: S&S® IST Ignition System for

1984-1999 Big Twin and Custom Applications

IMPORTANT NOTICE:





WARNING



CAUTION



NOTE

Other information of particular importance has been placed in italic type.

S&S recommends you take special notice of these items.

WARRANTY:

            

















  

            

    













ADDITIONAL WARRANTY PROVISIONS:











           

      





 





SAFE INSTALLATION AND OPERATION RULES:







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           

         



 



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         

      



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

 

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        



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

 

         





           

          



DISCLAIMER:

         

          



















         



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Instruction 51-1156

03-25-10



 





Summary of content (17 pages)

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S&S Cycle, Inc ® Instruction 51-1156 03-25-10 Copyright © 2003, 2006, 2010 by S&S® Cycle, Inc. . 14025 Cty Hwy G PO Box 215 Viola, Wisconsin 54664 Phone: 608-627-1497 • Fax: 608-627-1488 All rights reserved. Printed in the U.S.A. Technical Service Phone: 608-627-TECH (8324) Technical Service Email: sstech@sscycle.com Website: www.sscycle.
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Instruction Contents: A. Introduction B. Parts List C. Securing Motorcycle D. Removal of Existing Ignition Module E. S&S® System Installation F. Initial Starting and Operation Procedure G. Basic Troubleshooting H. Advanced Troubleshooting CAUTION Do not use a dual fire coil with the S&S ignition module. This kit will NOT work with vehicles equipped with flat slide carbs, open primaries, and dry clutches. If you want to use IST with these configurations contact S&S, we can help set up IST. A.
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NOTE: The electronics used in the S&S Ignition System require operation in single fire mode only. The S&S Ignition System cannot be used in dual fire mode. Ignition Coil Identification Dual Fire Coil In addition to the spark plug terminals, an aftermarket dual fire coil will have two wiring terminals: positive, negative.
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C. Securing Motorcycle CAUTION Motorcycle must be adequately secured against falling over during the Ignition system installation! Use of tie down straps on both sides of the motorcycle is recommended. WARNING Disconnect negative terminal of battery to eliminate potential sparks and inadvertent engagement of the starter while working on motorcycle. 1. P lace motorcycle on a suitable repair stand so that the motorcycle is stable and secure with the rear tire elevated. Place motorcycle in 4th or 5th gear.
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Installing components without removing the fuel tank is a timesaving suggestion only. If there is any reservation on the part of the installing mechanic about performing this installation with the fuel tank in place, refer to the appropriate service manual for correct procedure for removing fuel tank and related components. 1. Cylinder Head Temperature Sensor Installation. Harley-Davidson® Evolution® style engines use a special intake flange bolt with an integral temperature sensor. See Picture 5, below.
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c. A fter determining final position for Knock Sensor, remove mounting bolts and lockwashers, apply blue Loctite® 243 on first three threads of bolts, then re-install. Torque mounting block to cylinder head bolt to 33 ft.-lbs., torque knock sensor to mounting block bolt to 11 ft.-lbs. CAUTION • Knock Sensor must be mounted to the rear cylinder for correct operation. • Mounting the Knock Sensor on the front cylinder will provide an incorrect signal. • Do not over-tighten. Torque in excess of 20 ft.
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Slot Pin Picture 9 g. S ecure the sensor cup in place using the provided brass screw. Use Loctite® 243 (blue) on the first three threads and tighten securely (1520 in/ lbs.). NOTE: The non-magnetic 10-32 brass panhead screw provided in the installation kit must be used to attach the rotor to the end of the camshaft. Screws made of metal other than brass (including stainless steel) may affect the function of the VR sensor. h.
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Picture 10 Big Twin Picture 11 Sportster® models Alignment pin hole locations for initial timing. Pin holes must be located as pictured, at Top Dead Center of the compression stroke of the front cylinder Alignment pin locations for initial timing. Big twin is shown on the left, Harley-Davidson® Sportster® model is shown on the right. l. V isually align the holes in the sensor plate with the pins in the sensor cup. Gently slide the sensor plate into position onto the alignment pins.
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6. Installation of the IST Ignition Module and Main IST Wiring Harness: The Main IST Wiring Harness (See Picture 13, below) is a one-piece assembly consisting of the following connectors: (a) I ST Ignition Module Connector: 32-Socket, Gray (Delphi®/Packard®) - Connects to the S&S® Intelligent Spark Technology Ignition Module. (b) M otorcycle Main Harness Connector: 8-socket Black (Deutsch) – Connects to the stock Harley-Davidson® wiring harness in place of the stock module.
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NOTE: Locking tabs on each connector listed should produce a light “click” sound when properly assembled. S&S recommends checking each connection by lightly pulling on each half of the connector to ensure that the locking tabs have properly seated. h. Route harness segment (f) (See Picture 13, previous page) of the S&S® harness towards the coil. i ttach supplied separate coil wiring pigtail (also item “f”, but in picture 1 to main harness segment (f) in Picture 13).
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1970, the first year for the nosecone mounted ignition. This is not the case. Currently, the IST ignition is limited to 1984-up carbureted engines. The IST ignition requires input from an engine temperature sensor, not available at this time for pre-1984 shovelhead engines. 8. Motorcycles with a 7-pin connector instead of 8-pin connector Some Harley-Davidson® motorcycles manufactured between the years 1991 and 1994 had a 7-pin connector in place of the 8-pin connector.
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Pink tach wire in #4 is optional red/white black/white 3 2 Discard sealing pins from rear of connector 5 green/white Insert three wires from cam harness into rear of power harness. Insert wires fully, then replace locking wedge into front of connector. Picture 18 • rimp connections are preferred over soldered connections. Soldering causes stress concentrations at the wire to solder joint. Soldered C connections are prone to break in high vibration environments.
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f. Ride through intersections/stretches of road where second and third gear roll-ons are required. G. Basic Troubleshooting: Below are some suggestions if any problems are encountered with the IST Ignition Module. 1. Problem: Engine cranks but will not start. Possible solutions: a. Check that the gas tank is full and that the fuel petcock is turned on. b. Check that coil wires (plug and harness) have been reinstalled properly. c. Check that all connections are complete on the Wiring Harness Adapter. d.
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process. See Picture 19, below. Note position of connector lock Pin #1 Pin #2 Picture 19 CAUTION Do not cross any pins other than pins 1 & 2. e. Turn key to “on” Set off/run switch to run, but do not start engine. f. The check engine light will flash through its initial start sequence, as described above. g. A fter the initial sequence of flashes, stored trouble codes will then be sent out as a series of flashes. Trouble codes are stored as two digit numbers.
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Check Engine Lamp Code Diagnostic Test Condition (Code Reader Only) 12 P0107 MAP sensor open 12 P0108 MAP sensor high 12 P0109 MAP sensor intermittent 14 P0117 Engine Temp sensor voltage low 14 P0118 Engine Temp sensor voltage open 14 P0119 Engine Temp sensor voltage intermittent 71 P0324 Knock sensor low input 72 P0327 Knock sensor high input 41 P0335 Crank Position sensor intermittent 41 P0336 Crank Position sensor synch error 42 P0340 Cam sensor failure 16 P0562 Batte
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BE BK BN DK GN GY LT Blue Black Brown Dark Green Gray Light Wire Color O PK R TN V W Y Orange Pink Red Tan Violet White Yellow 1 2 1. BE/O = COIL (-) FRONT 2. W/BK = SWITCHED BATTERY POWER 3.
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