Manual

ManualsBrandsS&S Cycle ManualsFor motorcyclesIST Ignition System for 1984–99 4 1/8 Bore Big Twin Engines

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–’99 4⁄" Bore Big Twin Engines

IMPORTANT NOTICE:

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



WARNING

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

CAUTION

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

NOTE

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

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

WARRANTY:

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

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

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

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

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



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

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

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

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

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

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

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

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

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

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

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

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

ADDITIONAL WARRANTY PROVISIONS:

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



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

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

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

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

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

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

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

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

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

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

SAFE INSTALLATION AND OPERATION RULES:

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

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

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

 

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

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



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

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



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

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

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

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



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

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



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

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

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



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

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

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

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

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

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



DISCLAIMER:

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

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

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

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

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

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

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

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

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

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



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

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Instruction 51-1155

04-30-12



 





Summary of content (16 pages)

PAGE 1
S&S Cycle, Inc ® Instruction 51-1155 04-30-12 Copyright © 2009, 2010, & 2012 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. B. C. D. E. F. G. Introduction Parts List Removal of Existing Ignition Module S&S® System Installation Initial Starting and Operation Procedure Basic Troubleshooting 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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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. Single Fire Coil In addition to the spark plug terminals, an aftermarket single fire coil will have three wiring terminals: A negative terminal for the front cylinder, a common 12v + terminal, and negative terminal for the rear cylinder, this is the most common type of single fire coil.
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S&S® Ignition System Installation Kit 55-1050 contains the following items (See Picture 1, previous page): • S&S 41⁄8" Bore Engine Wiring Harness Adapter (S&S 55-1048) Item (a) • Cylinder Head Temperature Sensor (S&S 55-1014, Harley-Davidson® #32446-99) Item (b) • Crank Position Sensor (S&S 55-1051, H-D® #32798-00) and Hardware, Item (c) • MAP Sensor (S&S 55-1037, H-D® 32316-99) and Hardware, Item (d) • Coil Harness (S&S 55-1038) Item (e) • Loctite® and Wire Ties.
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Picture 5 Picture 6 2. Existing Coil, VOES, and Cam Position Sensor a. If so equipped, remove the existing dual fire ignition coil. This is usually located on the left side near the upper motor mount, above the engine front rocker box, or to the left of the engine near the seat. Remove or insulate the “+” and module terminals in the existing harness with heat shrink. b. If so equipped, remove the existing vacuum operated electrical switch (VOES). This is located between the heads.
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2. Installation of the Knock Sensor Kit 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. NOTE: There are two mounting locations possible for the knock sensor. Read the description of each location, and then examine your motorcycle for which one to use. The first location has better clearance than the second location, the knock sensor will work well in either one.
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CAUTION Hold knock sensor in position by hand only while torquing. Do NOT use pliers. Damage to knock sensor will occur. 3. Installation of the MAP Sensor a. Replace the existing VOES vacuum hose with the one provided. Trim the hose to a length that will locate the MAP Sensor so it does not interfere with the engine Temperature or Knock sensors, or motor mount hardware. A hose length in the 1 to 2 inch range is acceptable.
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• .200" Spacers (4) • .060" Spacers (4) • .475" O.D. Washers (2) • .250 I.D. Lockwashers (2) 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 insure that the locking tabs have properly seated. a.
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Picture 12 Picture 13 7. Motorcycles with a 7-pin ignition connector instead of an 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. A 7 to 8 pin adapter is available through aftermarket sources such as Drag Specialties (part #: DS-243068). It is a universal adapter that allows many different ignition systems (including the S&S IST ignition) to work on motorcycles with a 7-pin connector.
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NOTES: • Installer to source appropriate wire for any additions. Use supplied shrink tube and wire cover to insulate and protect wires and connections. • Stagger any splices in a wire harness bundle. This reduces the chance of wear between adjacent splices. It also makes it easier to pass splices wire through the harness sleeving. •C rimp connections are preferred over soldered connections. Soldering causes stress concentrations at the wire to solder joint.
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c. Check that all connections are complete on the Wiring Harness Adapter. 2. Problem: Key power-on switch does not seem to work. Possible solutions: a. Check for blown fuses and/or tripped circuit breakers. b. Check that the battery has been properly reconnected. c. Check that the connectors are connected correctly. G. Advanced Troubleshooting The S&S® ignition system features advanced self-diagnostic capabilities. The unit detects operational faults, and stores them as codes in memory.
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CAUTION See Picture 15 for pin locations. Do not connect any other pins except pins 1 & 2. Note position of connector lock Pin 1 Pin 2 Picture 15 e. Turn key to “on” and 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. After 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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IST Ignition Module P/Ns 55-1221 (AFfter Market Module) 55-1222 (Emmissions Engine Module w/Break-in Rev Limiter) 55-1223 (Module w/Break-in Rev Limiter) (Not Included with Installation Kit) XX/XX O PK R TN V W Y Orange Pink Red Tan Violet White Yellow Stripe Color WIRE COLOR/STRIPE KEY Blue Black Brown Dark Green Gray Light S&S 41⁄8" Bore Wiring Harness Adapter (Replacement P/N: 55-1048) Main Motorcycle Harness Crank Position Sensor (Replacement P/N: 55-1051) 4. W/BK = Switched Battery Power 5.
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