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techtalk:ref:engctl01a [2019/12/15 19:05] hippysmack [Study the Wiring Diagrams] |
techtalk:ref:engctl01a [2024/01/14 02:36] (current) hippysmack |
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| [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | ||
| - | ====== REF: Engine Control - Sub-01a ====== | + | ====== REF: Engine Control - Sub-01A ====== |
| - | ====== Sportster Sport 1200S '98-'03 Ignition Replacement ====== | + | ====== '98-'03 Sportster Sport 1200S Dynatek D2Ki-3P Ignition Conversion ====== |
| + | Article by steelworker of the XLFORUM ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/130785-sportster-sport-1200s-98-03-ignition-replacement?t=1382357)) \\ | ||
| - | <blockquote>Changing to an after market ignition system is something that will probably come to all 1200S owners eventually as stock and SE ignition components become more difficult to source. ((steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) **PLEASE NOTE**: by doing this mod, you will lose certain functions from the 1200S. Specifically, the diagnostic (fault code) function and the related check-engine light on the speedo, which are both tied into the stock ignition module. The frame-mount Sportster electrical system is so basic (and this modification will make it even more simple), that a diagnostic sytem with data-link can be considered more or less redundant. \\ | + | <blockquote>Changing to an after market ignition system is something that will probably come to all 1200S owners eventually as stock and SE ignition components become more difficult to source. ((steelworker of the XLFORUM)) **PLEASE NOTE**: by doing this mod, you will lose certain functions from the 1200S. Specifically, the diagnostic (fault code) function and the related check-engine light on the speedo, which are both tied into the stock ignition module. The frame-mount Sportster electrical system is so basic (and this modification will make it even more simple), that a diagnostic sytem with data-link can be considered more or less redundant. \\ |
| Swapping the ignition module means you also have to swap the coils, as most aftermarket systems require coils with a 3 ohm primary resistance, compared to 0.5 ohm for the stock 1200S coils. </blockquote> | Swapping the ignition module means you also have to swap the coils, as most aftermarket systems require coils with a 3 ohm primary resistance, compared to 0.5 ohm for the stock 1200S coils. </blockquote> | ||
| Line 18: | Line 19: | ||
| </blockquote> | </blockquote> | ||
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_1_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_8_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_1_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_8_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ |
| A Daytona Twin Tec VOES kit was used to replace the MAP sensor. This is set at 6-7 in-Hg, instead of the stock 3.5-4.5 In-Hg, to reduce spark knock during light load and throttle roll-on. The kit comes with mounting bracket, electrical connectors, instructions and a new hose then coupled with their timing rotor, which is basically the stock rotor for most Harleys except the 1200S. See rotor comparison on right pic below. \\ | A Daytona Twin Tec VOES kit was used to replace the MAP sensor. This is set at 6-7 in-Hg, instead of the stock 3.5-4.5 In-Hg, to reduce spark knock during light load and throttle roll-on. The kit comes with mounting bracket, electrical connectors, instructions and a new hose then coupled with their timing rotor, which is basically the stock rotor for most Harleys except the 1200S. See rotor comparison on right pic below. \\ | ||
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_4_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_5_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_27_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_4_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_5_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_27_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ |
| - | ====== Wiring and Diagrams ====== | + | ====== Wiring Diagrams ====== |
| - | + | ||
| - | VOES: \\ | + | |
| - | This system uses a VOES switch to replace the factory MAP unit. \\ | + | |
| - | A modified old broken stock coil/ignition switch bracket was used to take the ignition switch and VOES mounted under the front of the gas tank. \\ | + | |
| - | The wires to the VOES can be connected either way round - one in / one to earth. \\ | + | |
| - | Connect one of the wires to the violet wire from the Dynatek module and splice the other to the nearest earth lead. \\ | + | |
| - | The earth ground, at the old Data Link was used to connect the ignition module and starter relay. | + | |
| - | + | ||
| - | DYNATEK MODULE AND COILS: \\ | + | |
| - | + | ||
| - | * Violet wire - to VOES. | + | |
| - | * Green wire - is the tachometer feed. \\ Splice to the pink wire that originally ran to the black connector of the stock Ignition Module. | + | |
| - | * Pink wire - to Rear Coil (see diagram). \\ There is room for confusion here - do not be tempted to connect pink to pink, or something is going to get damaged! | + | |
| - | * Blue wire - to Front Coil (see diagram). | + | |
| - | * White / White - Black wires - \\ The wiring diagram that came with the module showed the White wire from the module connected to one coil, the switched power wire from the loom connected to the other coil, and the loop supplied with the kit connected between them. However, the Black/White switched power wire from the handlebars feeds the Dynatek module and both coils. So to reduce the number of wires going to the coils, a splice was made in the loom of the Black/White switched power wire, the White wire from the Dynatek Module, and one of the spare lengths of Black/White wire that were removed from the loom earlier. The latter was ran down to the front coil, with the loop supplied with the Dynatek kit connecting both coils (see the wiring diagrams below and Dynatek wiring diagram below for comparison). | + | |
| Click on a pic to enlarge: \\ | Click on a pic to enlarge: \\ | ||
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_49_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357&page=2)) {{:techtalk:ref:engctl:98_s_model_dyna_d2ki_iginition_conversion_drawing_by_hippysmack.jpg?direct&400|}} ((drawing by Hippysmack based from steelworker's drawing markup http://xlforum.net/forums/showthread.php?t=1382357&page=2)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_49_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_d2ki_iginition_conversion_drawing_by_hippysmack.jpg?direct&400|}} ((drawing by Hippysmack based from steelworker's drawing markup http://xlforum.net/forums/showthread.php?t=1382357&page=2)) \\ |
| - | From this stage, it's time to start cutting wires. \\ | + | ====== Removing the stock ignition and parts ====== |
| - | Remove the nylon braid and insulating tape from the area shown in red. \\ | + | |
| - | Under the braid on the main branch that sits behind the oil tank is a corrugated plastic sheath. \\ | + | |
| - | Remove it and put it aside to reinstall later. \\ | + | |
| - | ====== Remove the stock ignition parts ====== | + | |
| With the tank and seat removed, it's time to start stripping a few parts that won't be needed any more. \\ | With the tank and seat removed, it's time to start stripping a few parts that won't be needed any more. \\ | ||
| Line 56: | Line 38: | ||
| It also serves as a mount for a "spare" electrical connector for the air filter trapdoor solenoid on bikes registered in California. \\ | It also serves as a mount for a "spare" electrical connector for the air filter trapdoor solenoid on bikes registered in California. \\ | ||
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_11_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_11_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ |
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_12_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_13_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_14_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_12_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_13_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_14_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ |
| Remove the ignition cover to get to the stock ignition pick-up and timing rotor (if you have a stock cover, you'll need to drill out the two pop rivets that hold it in place). \\ | Remove the ignition cover to get to the stock ignition pick-up and timing rotor (if you have a stock cover, you'll need to drill out the two pop rivets that hold it in place). \\ | ||
| Line 67: | Line 49: | ||
| With a flat-head screwdriver, remove the two pillar bolts holding the pick-up in place and pry out the pickup to reveal the ignition rotor behind it. \\ | With a flat-head screwdriver, remove the two pillar bolts holding the pick-up in place and pry out the pickup to reveal the ignition rotor behind it. \\ | ||
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_15_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_15_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ |
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_16_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_17_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_18_by_steelworker.png?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_16_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_17_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_18_by_steelworker.png?direct&300|}} ((photo by steelworker)) \\ |
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_19_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_20_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_21_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_19_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_20_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_21_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ |
| Unclip and disconnect the three-pin Deutsch connector clipped to the rear of the bottom frame rail. \\ | Unclip and disconnect the three-pin Deutsch connector clipped to the rear of the bottom frame rail. \\ | ||
| Line 80: | Line 62: | ||
| Then remove the bolt holding the ignition rotor in place and remove the rotor. It will probably be quite stiff to pull out, but gently work it side-to-side to get it moving. \\ | Then remove the bolt holding the ignition rotor in place and remove the rotor. It will probably be quite stiff to pull out, but gently work it side-to-side to get it moving. \\ | ||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_22_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_23_by_steelworker.jpg?direct&300|}} ((photo by steelworker))\\ | ||
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_22_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_23_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357))\\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_24_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_25_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) |
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_26_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ | ||
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_24_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_25_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) | + | ===== Stock wiring removal ===== |
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_26_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) \\ | + | |
| + | Remove the nylon braid and insulating tape from the area shown in red. \\ | ||
| + | Under the braid on the main branch that sits behind the oil tank is a corrugated plastic sheath. \\ | ||
| + | Remove it and put it aside to reinstall later. \\ | ||
| + | It's a good idea to thread the Dynatek loom through the same route as the stock loom to see how much wire you have to play with. \\ | ||
| + | It also helps you know where you can splice them in. \\ | ||
| + | |||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_44_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) | ||
| + | |||
| + | Working from left to right, top to bottom, of the factory wiring diagram you'll see: \\ | ||
| + | |||
| + | MAP SENSOR: \\ | ||
| + | All three wires removed back to the gray connector of the Ignition Module. \\ | ||
| + | The Red/White wire is spliced to another Red/White coming from the Cam Position Sensor, which is also removed. \\ | ||
| + | |||
| + | DATA LINK: \\ | ||
| + | Black earth wire removed back to the first splice in the loom (this was later spliced in the earth lead from the new VOES switch). \\ | ||
| + | The other three wires are removed all the way back to the gray and black connectors of the Ignition Module. \\ | ||
| + | |||
| + | COIL: \\ | ||
| + | Yellow/Blue and Blue/Orange wires removed all the way back to the black connector of the Ignition Module. \\ | ||
| + | The White/Black wire is cut at the first splice in the loom. \\ | ||
| + | Trace the wire going forwards from this big splice. \\ | ||
| + | It is the main switched power wire from the Engine Stop/Run Switch to the Coil, Trapdoor Solenoid and Ignition Module (black connector) and spurs off to the Data Link. \\ | ||
| + | This will be used later to provide power to the new coils and to the Dynatek module. \\ | ||
| + | |||
| + | BANK ANGLE SENSOR: \\ | ||
| + | Light Green/Gray wire removed back to the black connector of the Ignition Module. \\ | ||
| + | Black wire removed back to the first splice. \\ | ||
| + | Grey wire removed back to the connector at the fuse block. \\ | ||
| + | The wiring diagram shows an in-line splice to the gray power wire coming from the fuse block, but the splice is actually at the fuse block. \\ | ||
| + | |||
| + | CAM POSITION SENSOR: \\ | ||
| + | Red/White wire removed completely (see MAP SENSOR above). \\ | ||
| + | Green/White wire removed back to the gray connector of the Ignition Module. \\ | ||
| + | Black/White wire removed back to the gray connector of the Ignition Module (including the splice to the MAP SENSOR - see above). \\ | ||
| + | |||
| + | TRAPDOOR SOLENOID: | ||
| + | Unless you live in California, this is the spare connector clipped to a plate on the right hand side of the top frame rail, above the carb. \\ | ||
| + | Black wire removed back to the first splice. \\ | ||
| + | White/Black wire removed back to the first splice (this is the big splice mentioned under COIL above). \\ | ||
| + | Green wire removed back to the first splice. \\ | ||
| + | |||
| + | IGNITION MODULE GRAY CONNECTOR: \\ | ||
| + | Having done all of the above, you should have disconnected all wires from this connector, and you can discard it. \\ | ||
| + | |||
| + | IGNITION MODULE BLACK CONNECTOR: \\ | ||
| + | Having done all of the above, you should have only three wires remaining on this connector: \\ | ||
| + | Black/Yellow - is the feed to the check engine light, which will not function with the new ignition module, so this is not required. \\ | ||
| + | Here it was shortened slightly, insulated and folded back into the harness. \\ | ||
| + | The check engine light may come in useful in the future as a warning light for some other function. \\ | ||
| + | (unless you want to pull the harness apart forward of the headstock). \\ | ||
| + | Black - remove back to the first splice. \\ | ||
| + | Pink - is the feed to the tachometer. \\ | ||
| + | You'll later need to connect the Violet wire from the Dynatek module to this wire. \\ | ||
| + | Cut the wire at the module and leave it long until you can offer up the wire from the Dynatek and decide where you want the splice to be. \\ | ||
| + | With all wires disconnected from this connector, you can discard it. \\ | ||
| + | |||
| + | That's all the wire cutting you have to do. \\ | ||
| - | ====== Install the new parts ====== | + | ====== Installing the new parts ====== |
| Fit the new rotor and screw. The Twin Tec rotor came with an Allen screw, washer and lock washer. Also, use Loctite 243 on the screw. \\ | Fit the new rotor and screw. The Twin Tec rotor came with an Allen screw, washer and lock washer. Also, use Loctite 243 on the screw. \\ | ||
| Line 94: | Line 135: | ||
| Secure the module with the two pillar bolts. Don't re-fit the covers yet. Later you'll need to set the timing when all the electrics are connected up. \\ | Secure the module with the two pillar bolts. Don't re-fit the covers yet. Later you'll need to set the timing when all the electrics are connected up. \\ | ||
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_29_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_30_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_29_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_30_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) |
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_31_by_steelworker_copy.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_31_by_steelworker_copy.jpg?direct&300|}} ((photo by steelworker)) \\ |
| Time to attack the wiring loom. This is where it could get a little bit scary. \\ | Time to attack the wiring loom. This is where it could get a little bit scary. \\ | ||
| Line 105: | Line 146: | ||
| With the battery out of the way, remove the rubber tray liner and the fasteners holding the battery tray in place (these three bolts, plus one nut under the tray). \\ | With the battery out of the way, remove the rubber tray liner and the fasteners holding the battery tray in place (these three bolts, plus one nut under the tray). \\ | ||
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_33_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_34_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_33_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_34_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) |
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_35_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_35_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ |
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_36_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_37_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_36_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_37_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) |
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_38_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_38_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ |
| As you remove the battery tray, disconnect the bank angle sensor bolted to the rearward side of it. \\ | As you remove the battery tray, disconnect the bank angle sensor bolted to the rearward side of it. \\ | ||
| Line 117: | Line 158: | ||
| Remove the Deutsch connector for the speedo drive from the frame and disconnect it. Fold both ends out of the way, as this all needs to stay as it is. \\ | Remove the Deutsch connector for the speedo drive from the frame and disconnect it. Fold both ends out of the way, as this all needs to stay as it is. \\ | ||
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_39_by_steelworker.jpg?direct&200|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_40_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_41_by_steelworker.jpg?direct&200|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_39_by_steelworker.jpg?direct&200|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_40_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_41_by_steelworker.jpg?direct&200|}} ((photo by steelworker)) \\ |
| Disconnect the wires to the rear lights and turn signals and the connector to the turn signal module that's bolted to the fender. \\ | Disconnect the wires to the rear lights and turn signals and the connector to the turn signal module that's bolted to the fender. \\ | ||
| Line 128: | Line 169: | ||
| Inside here are a bunch of large splices, which HD, in their infinite wisdom, chose to place close together and directly in line with the boss for the fuel tap, making the loom thickest at exactly the point where it's the tightest fit under the tank. \\ | Inside here are a bunch of large splices, which HD, in their infinite wisdom, chose to place close together and directly in line with the boss for the fuel tap, making the loom thickest at exactly the point where it's the tightest fit under the tank. \\ | ||
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_43_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_44_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_45_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_43_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_44_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_45_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ |
| + | |||
| + | Below, the sleeved wires from the Dynatek module are routed alongside the wires to / from the regulator/rectifier, neutral switch and oil pressure switch. \\ | ||
| + | (none of which should be affected by this install). \\ | ||
| + | The second pic shows the dismantling the loom where it appears from behind the transmission / starter motor. \\ | ||
| + | Remove that plastic sleeve and save it to go back on later. It's really not as bad as it looks. \\ | ||
| + | |||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_50_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/130785-sportster-sport-1200s-98-03-ignition-replacement/page2?t=1382357&page=2)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_51_by_steelworker.jpg?direct&200|}} ((photo by steelworker of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/130785-sportster-sport-1200s-98-03-ignition-replacement/page2?t=1382357&page=2)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_52_by_steelworker.jpg?direct&300|}} ((photo by steelworker of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/130785-sportster-sport-1200s-98-03-ignition-replacement/page2?t=1382357&page=2)) \\ | ||
| + | |||
| + | Here is the old cracked stock coil / ignition switch bracket to be salvaged for use as a VOES mounting bracket. \\ | ||
| + | The new VOES location is where the stock coils were. \\ | ||
| + | |||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_53_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_54_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ | ||
| + | |||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_55_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) | ||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_56_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ | ||
| + | |||
| + | |||
| + | The (slightly reduced) wiring loom was wrapped to hold everything in place whilst connecting the Dynatek wires to the VOES and coils. \\ | ||
| + | The braided sleeve is from the dynatek module, and the smaller wire is from the speedo drive. \\ | ||
| + | You can see the VOES, ignition switch and front directional indicator block connector below. \\ | ||
| + | |||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_57_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ | ||
| + | |||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_58_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_59_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) | ||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_60_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ | ||
| + | |||
| + | Here are the coil connections looking up behind the coil bracket. \\ | ||
| + | The cables are tied to a little plastic harness stuck to the back of the coil bracket to keep them away from the cylinders. \\ | ||
| + | You can see the rear end of the loom sleeve. \\ | ||
| + | There was a faint crackling sound as the battery earth lead was connected which was the aluminised coating on the sleeve shorting on the live terminal. \\ | ||
| + | So it was trimmed back a bit. \\ | ||
| + | |||
| + | The revised underseat layout shows a bit more room now that the stock ignition module is out of the way. \\ | ||
| + | A couple of blanking grommets were used to fill the holes in the frame cross-member where the stock ignition module mounts. \\ | ||
| + | |||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_61_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_62_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) | ||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_63_by_steelworker.jpg?direct&200|}} ((photo by steelworker)) \\ | ||
| + | |||
| + | All hooked up. \\ | ||
| + | |||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_64_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_65_by_steelworker.jpg?direct&200|}} ((photo by steelworker)) | ||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_66_by_steelworker.jpg?direct&200|}} ((photo by steelworker)) \\ | ||
| + | |||
| + | ===== New parts wiring ===== | ||
| + | |||
| + | VOES: \\ | ||
| + | This system uses a VOES switch to replace the factory MAP unit. \\ | ||
| + | A modified old broken stock coil/ignition switch bracket was used to take the ignition switch and VOES mounted under the front of the gas tank. \\ | ||
| + | The wires to the VOES can be connected either way round - one in / one to earth. \\ | ||
| + | Connect one of the wires to the violet wire from the Dynatek module and splice the other to the nearest earth lead. \\ | ||
| + | The earth ground, at the old Data Link was used to connect the ignition module and starter relay. | ||
| + | |||
| + | DYNATEK MODULE AND COILS: \\ | ||
| + | |||
| + | * Violet wire - to VOES. | ||
| + | * Green wire - is the tachometer feed. \\ Splice to the pink wire that originally ran to the black connector of the stock Ignition Module. | ||
| + | * Pink wire - to Rear Coil (see diagram). \\ There is room for confusion here - do not be tempted to connect pink to pink, or something is going to get damaged! | ||
| + | * Blue wire - to Front Coil (see diagram). | ||
| + | * White / White - Black wires - \\ The wiring diagram that came with the module showed the White wire from the module connected to one coil, the switched power wire from the loom connected to the other coil, and the loop supplied with the kit connected between them. However, the Black/White switched power wire from the handlebars feeds the Dynatek module and both coils. So to reduce the number of wires going to the coils, a splice was made in the loom of the Black/White switched power wire, the White wire from the Dynatek Module, and one of the spare lengths of Black/White wire that were removed from the loom earlier. The latter was ran down to the front coil, with the loop supplied with the Dynatek kit connecting both coils (see the wiring diagrams below and Dynatek wiring diagram below for comparison). | ||
| + | |||
| + | ====== Timing the ignition ====== | ||
| + | |||
| + | Before I started on this - before I bought the module even - I phoned Dynatek's very helpful tech support line for their recommendations for twin-plug engines, which do not need as much total advance as single-plug applications. They suggested to set the static timing with the crank at 4 degrees after top dead centre (rather than at TDC) compression stroke on the front cylinder. This coincides with the TDC mark in line with the right hand edge of the inspection hole (i.e. about to disappear past it). This may make dynamic timing of the motor with a timing light difficult or impossible. Having an assistant will make this part a lot easier. \\ | ||
| + | |||
| + | With the back wheel off the ground, the transmission in 5th gear (rock the rear wheel backwards and forwards while pulling up on the gear lever) and both plugs on the left hand side removed, get your assistant to rotate the rear wheel forwards until you can see (through the front cylinder spark plug hole) the inlet valve opening, then continue until the valve closes and the piston appears again and is near the top of its stroke. This ensures you are on compression stroke, rather than exhaust stroke. \\ | ||
| + | |||
| + | Now remove the allen head plug from the inspection hole below the base of the barrels on the right hand side. Look for the TDC timing mark (a vertical line, not the twin dots) to appear in the window as your assistant slowly nudges the wheel forwards (it doesn't take much effort, and you may end up going backwards and forwards a few times) and is in line with the right hand side of the inspection hole as you look at it. \\ | ||
| + | |||
| + | With a flat-blade screwdriver, loosen the two pillar bolts holding the Dynatek module in place, and rotate it slowly to cause the red LED to turn off and on. Find the point where the LED just turns off while rotating the module in a clockwise direction. Tighten the two pillar bolts to hold the module in position. Static timing is now set. Shift the transmission into neutral again, and replace the spark plugs. \\ | ||
| + | |||
| + | The switches on the module should be set to suit your engine's particular state of tune. I'll give the settings I'm using below for information, but they may not suit a stock motor. \\ | ||
| + | |||
| + | These are the Dynatek instructions: \\ | ||
| + | |||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_67_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) | ||
| + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_68_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ | ||
| + | |||
| + | My settings: \\ | ||
| + | Switch 1 OFF - Normal VOES mode, should be set here for most street motors. \\ | ||
| + | Switch 2 ON / Switch 3 OFF - Curve 2 - a suitable starting point for most street motors. \\ | ||
| + | Less initial advance, which should help with the slightly higher compression ratio of the 1200S, and with stage 2 XB heads I'm running higher compression than stock. \\ | ||
| + | Switch 4 OFF / Switch 5 ON - 7,000rpm rev limit, which is ok for the valve train I'm running, but with a stock 1200S I'd stick to 6,000rpm (6,500rpm absolute MAXIMUM). \\ | ||
| + | Switch 6 ON - single fire mode, which you should use if using this ignition set-up, with the coils wired as I have done. \\ | ||
| + | |||
| + | VERDICT: \\ | ||
| + | Delighted. On an initial road test last weekend it felt very good. I think my old SE module had been deteriorating for a while, but now the bike has certainly got its punch back, and no signs of pinking even when I tried to ride in a way that might make it do so. Unless you've been hoarding stock or SE ignition components, this conversion is something that all 1200S owners are likely to have to do at some point, and I think it's worth doing before it becomes necessary. I may replace the stamped ignition rotor with a machined ignition rotor from NRHS for the sake of insurance. It might have been nice to keep the bank angle sensor, but I could not see a way of making that work with the Dynatek module, and I'm not really bothered about it. \\ | ||
| + | It's impossible to say if there was any noticeable performance difference, as there are other variables - better coils, and a new ignition module instead of the stock (and, before that, deteriorating SE) modules. It does feel and sound a lot crisper, it starts easier, and seat of the pants dyno says it goes a lot better. There is certainly no noticeable on/off as the VOES switches - just smooth power all the way. In theory, a MAP sensor is a better unit than a VOES, allowing a range of advance curves instead of the on/off VOES switch, but any loss there has been swallowed up by gains from the other components. \\ | ||
| + | You can buy the cable and software to be able to make custom advance curves (it costs another ninety something dollars). But the Dynatech tech support guy advised that the range of curves available on the switches would be sufficient for most bikes. The programmable software would enable, for instance, setting the static timing at TDC and then playing around with the total advance, rather than setting static timing at just past TDC as I have done. When uploading a curve from the programmable software, it overrides the switches on the module, which can later be re-enabled if desired by reconnecting and "turning off" the uploaded program. The '98-'03 1200S models all had the same ignition system so it will work on all of them. \\ | ||
| + | One thing I had issues with was the ground wire for the programming cable. The ring lug that was put on that cable is cheap and had an intermittent connection that took me a long time to figure out (and I ended up stripping the battery connection). The only time it matters is when you try to connect it to a computer. If the ground wire is not perfect, the software will never "see" the module. ((Airbozo of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/130785-sportster-sport-1200s-98-03-ignition-replacement/page3?t=1382357&page=3)) \\ | ||
