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techtalk:ref:engctl01a [2019/12/15 21:19] hippysmack [Sportster Sport 1200S '98-'03 Dynatek D2Ki-3P Ignition Conversion] |
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 ====== |
| ====== '98-'03 Sportster Sport 1200S Dynatek D2Ki-3P Ignition Conversion ====== | ====== '98-'03 Sportster Sport 1200S Dynatek D2Ki-3P Ignition Conversion ====== | ||
| - | Article by steelworker of the XLFORUM ((http://xlforum.net/forums/showthread.php?t=1382357)) \\ | + | 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 19: | 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 Diagrams ====== | ====== Wiring Diagrams ====== | ||
| 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)) \\ |
| ====== Removing the stock ignition and parts ====== | ====== Removing the stock ignition and parts ====== | ||
| Line 38: | 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 49: | 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 62: | 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)) | + | |
| - | {{: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)) \\ | + | |
| ===== Stock wiring removal ===== | ===== Stock wiring removal ===== | ||
| Line 76: | Line 75: | ||
| It also helps you know where you can splice them in. \\ | 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 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)) |
| Working from left to right, top to bottom, of the factory wiring diagram you'll see: \\ | Working from left to right, top to bottom, of the factory wiring diagram you'll see: \\ | ||
| Line 136: | 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 147: | 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 159: | 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 170: | 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. \\ | Below, the sleeved wires from the Dynatek module are routed alongside the wires to / from the regulator/rectifier, neutral switch and oil pressure switch. \\ | ||
| Line 177: | Line 176: | ||
| Remove that plastic sleeve and save it to go back on later. It's really not as bad as it looks. \\ | 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 http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?t=1382357&page=2)) \\ | + | {{: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. \\ | 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. \\ | 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 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357&page=2)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_54_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_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 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357&page=2)) | + | {{: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 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357&page=2)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_56_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ |
| Line 192: | Line 191: | ||
| You can see the VOES, ignition switch and front directional indicator block connector below. \\ | 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 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357&page=2)) \\ | + | {{: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 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357&page=2)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_59_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_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 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357&page=2)) \\ | + | {{: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. \\ | Here are the coil connections looking up behind the coil bracket. \\ | ||
| Line 206: | Line 205: | ||
| A couple of blanking grommets were used to fill the holes in the frame cross-member where the stock ignition module mounts. \\ | 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 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357&page=2)) {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_62_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_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 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357&page=2)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_63_by_steelworker.jpg?direct&200|}} ((photo by steelworker)) \\ |
| All hooked up. \\ | All hooked up. \\ | ||
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_64_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_iginition_swap_65_by_steelworker.jpg?direct&200|}} ((photo by steelworker of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357&page=2)) | + | {{: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 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357&page=2)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_66_by_steelworker.jpg?direct&200|}} ((photo by steelworker)) \\ |
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| ===== New parts wiring ===== | ===== New parts wiring ===== | ||
| Line 232: | Line 229: | ||
| * Blue wire - to Front Coil (see diagram). | * 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). | * 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 ====== | ====== Timing the ignition ====== | ||
| Line 248: | Line 244: | ||
| These are the Dynatek instructions: \\ | These are the Dynatek instructions: \\ | ||
| - | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_67_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_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 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1382357&page=2)) \\ | + | {{:techtalk:ref:engctl:98_s_model_dyna_iginition_swap_68_by_steelworker.jpg?direct&300|}} ((photo by steelworker)) \\ |
| My settings: \\ | My settings: \\ | ||
| Line 265: | Line 261: | ||
| 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. \\ | 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 http://xlforum.net/forums/showthread.php?t=1382357&page=3)) \\ | + | 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)) \\ |
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