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techtalk:evo:engctl01 [2022/10/12 21:39] – ixl2relaxtechtalk:evo:engctl01 [2024/07/21 02:26] (current) – [Manually Trigger The Ignition Control Module For Testing Spark] ixl2relax
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 **Heat Test - Method #1** - If the bike usually fires when cold but dies when warm/hot, test the ICM with the engine cold. With a cold engine, use a hair dryer to blow heat on the ICM (in the nosecone) before attempting to start it. After it's warm, see if the engine fails to start due to the spark missing or intermittent. **Heat Test - Method #1** - If the bike usually fires when cold but dies when warm/hot, test the ICM with the engine cold. With a cold engine, use a hair dryer to blow heat on the ICM (in the nosecone) before attempting to start it. After it's warm, see if the engine fails to start due to the spark missing or intermittent.
  
-**Heat Test - Method #2** - Once you have a running failure from heat, use 'cold spray' to quickly cool down the ICM (in the nosecone). If the ICM has failed due to heat, this test will check if it will begin to produce a spark again after being cooled down.+**Heat Test - Method #2** - The alternative is to use Cold Spray (see note below). Once you have a running failure from heat, use the cold spray to quickly cool down the ICM (in the nosecone). If the ICM has failed due to heat, this test will check to see if it will begin to produce a spark again after being cooled down.
  
-Somtimes, these two methods can be used in combination to create & resolve a failure condition, although heat related problems can still be hard to diagnose/resolve. The same procedures can be used to test the ignition coil for heat failure.+Somtimes, these two methods can be used in combination to create & resolve a failure condition, although heat related problems can still be hard to diagnose/resolve. The same two procedures can be used to test the ignition coil (or other aftermarket ignitions or  misc. electronic components) for heat failure. 
 + 
 +**'Cold Spray'** is a different form of the 134A A/C coolant. It can also be labeled as 134 Spray, 134A Spray, Freeze Spray, Component Cooler, etc. One version is Chemtronics Duster ES-1017. Don't confuse this with other medical-type freeze spray which should not be used because they include topical ingredients. Be sure the product you get has No Residue. The right product is pure 1,1,1,2-tetrachluoroethane.
  
 __The 1998-2003 1200Sport model__ used an independent Ignition Control Module and the same Sensor Plate as the 1986-1997 models. The 1200Sport model pioneered the Single-fire Spark system and the Manifold Air Pressure sensor (MAP) for the future Sportster models. __The 1998-2003 1200Sport model__ used an independent Ignition Control Module and the same Sensor Plate as the 1986-1997 models. The 1200Sport model pioneered the Single-fire Spark system and the Manifold Air Pressure sensor (MAP) for the future Sportster models.
  
-Like the other 1998-2003 models, the 1200Sport ICM is no longer available from the MoCo. Some have coverted to using the aftermarket nosecone ICM as mentioned above for the non-1200Sport models. (See Aftermarket Ignition Swap: [[http://xlforum.net/forums/showthread.php?t=1382357]] ((Article by steelworker of the XLFORUM)) )+Like the other 1998-2003 models, the 1200Sport ICM is no longer available from the MoCo. Some have converted to using the aftermarket nosecone ICM as mentioned above for the non-1200Sport models. (See Aftermarket Ignition Swap: [[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]] ((Article by steelworker of the XLFORUM)) )
  
 ^  OEM Ignition Control Modules (Latest Known Superceded Version)  ||||| ^  OEM Ignition Control Modules (Latest Known Superceded Version)  |||||
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 | Pin11 | LtGREEN/Red | Data Link (Pin1) | ... | Pin11 | BLACK | Harness Ground | | Pin11 | LtGREEN/Red | Data Link (Pin1) | ... | Pin11 | BLACK | Harness Ground |
 | Pin12 | VIOLET/Red | Data Link (Pin3) | ... | Pin12 | PINK | Signal to TACH (RPM out) | | Pin12 | VIOLET/Red | Data Link (Pin3) | ... | Pin12 | PINK | Signal to TACH (RPM out) |
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-| {{:techtalk:evo:engctl:ignitionsystem-81-97.jpg?400|}}\\ {{:techtalk:evo:engctl:ignitionsystem-98-03-nots.jpg?400|}}\\ {{:techtalk:evo:engctl:ignitionsystem-98-03-smodel.jpg?400|}} | {{:techtalk:evo:engctl:ignitionsystem-04-later.jpg?400|}}\\ {{:techtalk:evo:engctl:camsensorplate-icm-98-03-a.jpg?400|}} |+| {{:techtalk:evo:engctl:ignitionsystem-81-97.jpg?400|}}\\ {{:techtalk:evo:engctl:ignitionsystem-98-03-nots.jpg?400|}}\\ {{techtalk:evo:engctl:ignitionsystem-98-03-1200smodel.jpg?400|}} | {{:techtalk:evo:engctl:ignitionsystem-04-later.jpg?400|}}\\ {{:techtalk:evo:engctl:camsensorplate-icm-98-03-a.jpg?400|}} |
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 ==== 2004-2006 ==== ==== 2004-2006 ====
-The Ignition Control Module (ICM) became more capable and included a digital communications link (SDB) between itself, the Turn Signal Module and the Speedometer. This new Serial Data Bus (SDB), using an accessible data port on the side of the bike, also allowed the ICM to be dealer programmed for either 883 engines or 1200 engines, with upgrades as well.+The Ignition Control Module (ICM) for 2004-2006 became more capable and included a digital communications link (SDB) between itself, the Turn Signal Module and the Speedometer. This new Serial Data Bus (SDB), using an accessible data port on the side of the bike, also allowed the ICM to be dealer programmed for either 883 engines or 1200 engines, with upgrades as well.
  
 The newly added Crankshaft Position Sensor (CKP) replaced the camshaft pickup as a more advanced means of sensing the engine revolutions and the new Manifold Air Pressure sensor (MAP) replaced the VOES as a more advanced means of sensing engine loads. The ignition system gives a spark near top dead center for starting. Then, at running RPM and loads above this, the system gives a spark advance that varies between 0 and 40. (For further information, see the section below titled: 2004-later Single-fire Spark Synchronization) The newly added Crankshaft Position Sensor (CKP) replaced the camshaft pickup as a more advanced means of sensing the engine revolutions and the new Manifold Air Pressure sensor (MAP) replaced the VOES as a more advanced means of sensing engine loads. The ignition system gives a spark near top dead center for starting. Then, at running RPM and loads above this, the system gives a spark advance that varies between 0 and 40. (For further information, see the section below titled: 2004-later Single-fire Spark Synchronization)
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 From this point forward, all the Sportster models used a Single-fire Spark system, using two individual coil trigger wires to produce a spark on individual spark plugs, one at a time. (see coil information) From this point forward, all the Sportster models used a Single-fire Spark system, using two individual coil trigger wires to produce a spark on individual spark plugs, one at a time. (see coil information)
  
-The Ignition Control Module for these years is programmable by the dealer to match the specific model bike, either 883 or 1200. It is mounted under the seat. The part number on the ignition module is really the version of the internal software that was last flashed into the module. The module may have started out as a 32478-04 (or 32622-04) module, but it might then have been upgraded to 32622-04A. Later built models would have had the latest upgraded part installed from the factory. As of 2020, the 32622-04C is listed as correct for all 2004-2006 models (then programmed for 883 or 1200) and older modules are recommended to be upgraded to that level.+The Ignition Control Module for these years is programmable by the dealer to match the specific model bike, either 883 or 1200. It is mounted under the seat. The part number on the ignition module is really the version of the internal software that was last flashed into the module. The module may have started out as a 32478-04 (or 32622-04) module, but it might then have been upgraded to 32622-04A. Later built models would have had the latest upgraded part (software) installed from the factory. As of 2020, the 32622-04C is listed as correct for all 2004-2006 models (then programmed for 883 or 1200) and older modules are recommended to be upgraded to that level.
  
 It is believed that the stock RPM Limit is set for 6000 for 883 models and 5500 for 1200 models((These values are assumed to reflect the like values for the 2003 883 & 1200S model Sportsters)). The 2005 Owner's Manual says that 6000 RPMs is the maximum safe RPM but does not specify to which engine version that applies. The 883 Tuning Image on TechTip#58-2004-12-06 shows a Rev Limit of 5500 RPMs. For various models, some owners have suggested 5400, 5800 or 6000. It is believed that the stock RPM Limit is set for 6000 for 883 models and 5500 for 1200 models((These values are assumed to reflect the like values for the 2003 883 & 1200S model Sportsters)). The 2005 Owner's Manual says that 6000 RPMs is the maximum safe RPM but does not specify to which engine version that applies. The 883 Tuning Image on TechTip#58-2004-12-06 shows a Rev Limit of 5500 RPMs. For various models, some owners have suggested 5400, 5800 or 6000.
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 ==== 2007-2013 ==== ==== 2007-2013 ====
-With the implementation of Electronic Fuel Injection, the Electronic Control Module (ECM) is the heart of the ignition system. It obtains inputs and controls outputs as listed below. This expanded capability for the ECM allows it to be programmed in minute detail to account for changing conditions in the operating engine.+With the implementation of Electronic Fuel Injection, the Electronic Control Module (ECM) for the 2007-2013 models is the heart of the ignition system. It obtains inputs and controls outputs as listed below. This expanded capability for the ECM allows it to be programmed in minute detail to account for changing conditions in the operating engine.
  
 The ECM obtains input information from: The ECM obtains input information from:
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 ==== 2014-later ==== ==== 2014-later ====
-To further expand the computerization of the Sportster, the ECM was equipped with a Controller Area Network Bus (CANBUS) and the Body Control Module (BCM) was added. In general terms, the CANBUS replaced the digital communications between the smart controllers (in place of the Serial Data Bus) and allowed computerization of the handlebar controls, while the BCM replaced the Turn Signal Module and handled power distribution throughout the bike, including to the lights and other components. The BCM also eliminated all relays.+To further expand the computerization of the Sportster, the ECM for the 2014-later models was equipped with a Controller Area Network Bus (CANBUS) and the Body Control Module (BCM) was added. In general terms, the CANBUS replaced the digital communications between the smart controllers (in place of the Serial Data Bus) and allowed computerization of the handlebar controls, while the BCM replaced the Turn Signal Module and handled power distribution throughout the bike, including to the lights and other components. The BCM also eliminated all relays.
  
 ^ Year ^ Module P/N | Function | ^ Year ^ Module P/N | Function |
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 \\ \\
  
 +==== Ignition Timing - Adjustable 1986 Thru 2003 ====
  
-==== Ignition Timing - All Models 1986 Thru 2003 ==== +  * Ignition timing is when the spark takes place - specifically as the piston is traveling UP on the COMPRESSION stroke (compressing the gasses so that you get the most out of the explosion/ignition). ((Moved On / My Own Choice https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/55778-function-of-the-map-sensor/page2?t=278587&highlight=map+sensor&page=2)) 
- +  * Top Dead Center is when the piston is at the VERY top of its travel, in the center of it's dwell area, and is usually referenced to mean on TDC of the COMPRESSION stroke (with the valves closed and the mixture compressed), though the piston will also be at TDC on the Exhaust stroke when the flywheel turns one complete rotation in either direction from TDC of compression. ((Moved On / My Own Choice https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/55778-function-of-the-map-sensor/page2?t=278587&highlight=map+sensor&page=2)) So, the piston will be at TDC twice per 1 full revolution of the cams. Timing is measured (and set) from TDC on the compression stroke. Check below for the images of cam notch on timing rotor position relative to TDC Compression or see more on [[techtalk:ref:svcproc22#reftroubleshooting_-_engine_-_05|Finding TDC on Compression Stroke]] in the Sportsterpedia. 
-  * Ignition timing is when the spark takes place - specifically as the piston is traveling UP on the COMPRESSION stroke (compressing the gasses so that you get the most out of the explosion/ignition). ((Moved On / My Own Choice http://xlforum.net/forums/showthread.php?t=278587&highlight=map+sensor&page=2)) +  * Spark ADVANCE - is how soon, BEFORE the piston reaches top dead center (all proper timing is BEFORE TDC) that the spark plug fires to start burning the mixture. The faster the motor is turning, the sooner you need to start the ignition (more advanced it needs to be) so that the power of the expanding gasses starts pushing on that piston as soon as it starts moving downward and pushes as long as will be beneficial. ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/55778-function-of-the-map-sensor?t=278587)) 
-  * Top Dead Center is when the piston is at the VERY top of its travel, in the center of it's dwell area, and is usually referenced to mean on TDC of the COMPRESSION stroke (with the valves closed and the mixture compressed), though the piston will also be at TDC on the Exhaust stroke when the flywheel turns one complete rotation in either direction from TDC of compression. ((Moved On / My Own Choice http://xlforum.net/forums/showthread.php?t=278587&highlight=map+sensor&page=2)) So, the piston will be at TDC twice per 1 full revolution of the cams. Timing is measured (and set) from TDC on the compression stroke. Check below for the images of cam notch on timing rotor position relative to TDC Compression or see more on [[techtalk:ref:svcproc22#reftroubleshooting_-_engine_-_05|Finding TDC on Compression Stroke]] in the Sportsterpedia. +    * Ignite it too soon, and the gasses start pushing down as the piston is still coming up (spark knock, pinging etc). ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/55778-function-of-the-map-sensor?t=278587)) 
-  * Spark ADVANCE - is how soon, BEFORE the piston reaches top dead center (all proper timing is BEFORE TDC) that the spark plug fires to start burning the mixture. The faster the motor is turning, the sooner you need to start the ignition (more advanced it needs to be) so that the power of the expanding gasses starts pushing on that piston as soon as it starts moving downward and pushes as long as will be beneficial. ((http://xlforum.net/forums/showthread.php?t=278587)) +    * Ignite it too late, and you loose a lot of the power of the gases, since the piston will reach bottom before the gasses finish expanding. ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/55778-function-of-the-map-sensor?t=278587))
-    * Ignite it too soon, and the gasses start pushing down as the piston is still coming up (spark knock, pinging etc). ((http://xlforum.net/forums/showthread.php?t=278587)) +
-    * Ignite it too late, and you loose a lot of the power of the gases, since the piston will reach bottom before the gasses finish expanding. ((http://xlforum.net/forums/showthread.php?t=278587))+
  
 +^  The timings and rpms in the following chart are from the Factory Service Manuals for the various years.  ||||||
 ^ Year ^  0°=TDC\\ Timing Mark  ^  20°BTDC Adv\\ Timing Mark  ^  40°BTDC Adv\\ Timing Mark  ^  Timing Hole\\ on Engine  ^  Notes  | ^ Year ^  0°=TDC\\ Timing Mark  ^  20°BTDC Adv\\ Timing Mark  ^  40°BTDC Adv\\ Timing Mark  ^  Timing Hole\\ on Engine  ^  Notes  |
-| 1986-90 | Vertical Line | Single Dot |  None  |  Left Side  | Approx. 1000rpm=20°Adv - Using Timing Light - Look for Single Dot - 4sp Trans| +| 1986-90 | Vertical Line |  None  |  Single Dot  |  Left Side  | Set Idle = 1650-1950rpm - Use Timing Light - Look for Single Dot (40°) - 4sp Trans Models| 
-| 1991-95 | Vertical Line | Single Dot |  None  |  Right Side  | Approx. 1000rpm=20°Adv - Using Timing Light - Look for Single Dot - 5sp Trans| +| 1991-95 | Vertical Line |  None  |  Single Dot  |  Right Side  | Set Idle = 1650-1950rpm - Use Timing Light - Look for Single Dot (40°) - 5sp Trans Models| 
-| 1996-99 | Vertical Line | Double Dots |  Some-SingleDot  |  Right Side  | Approx. 1000rpm=20°Adv - Using Timing Light - Look for Double Dots | +| 1996-99\\ 2000-03 | Vertical Line | Double Dots |  Some-SingleDot  |  Right Side  | Set Idle = 1000-1050rpm - Use Timing Light - Look for Double Dots (20°) \\ 2000-2003 have Press Fit Flywheel |
-| 2000-03 | Vertical Line | Double Dots |  Some-SingleDot  |  Right Side  | Approx. 1000rpm=20°Adv - Using Timing Light - Look for Double Dots - Press Fit Flywheel |+
 | 2001-03 1200S models || These models need a Dynamic Timing of 15° BTDC when at Approx. 1000rpm (The ICM changed curves for these years)((2003 FSM 99484-03)) |||| | 2001-03 1200S models || These models need a Dynamic Timing of 15° BTDC when at Approx. 1000rpm (The ICM changed curves for these years)((2003 FSM 99484-03)) ||||
 |  The Timing Hole Plug (HD P/N 720) can be removed with a 3/8" Allen Hex Key - It has 5/8-18 threads  |||||| |  The Timing Hole Plug (HD P/N 720) can be removed with a 3/8" Allen Hex Key - It has 5/8-18 threads  ||||||
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 Important: Be sure you are on the compression stroke of the front cylinder when setting the Static Timing. When you rotate the engine (as follows) be sure you feel the pressure in the front cylinder spark plug hole is building up as you rotate toward the TDC mark. Turn the engine over as often as necessary to guarantee you are on the compression stroke of the front cylinder. Important: Be sure you are on the compression stroke of the front cylinder when setting the Static Timing. When you rotate the engine (as follows) be sure you feel the pressure in the front cylinder spark plug hole is building up as you rotate toward the TDC mark. Turn the engine over as often as necessary to guarantee you are on the compression stroke of the front cylinder.
  
-The Nosecone Ignition unit (98-03 not-S) can be **statically** timed (without the engine running) using the built-in LED. The procedure is to manually rotate the engine (bike on lift, 5th gear, rotate rear tire to rotate engine) to position the engine to TDC (front cylinder compression stroke) using the timing hole to look for & center the vertical line. Then, turn the ICM/Cam Sensor Plate slightly clockwise & counterclockwise to find the exact spot where the light switches between on & off - Lock down the plate.((aswracing comments http://xlforum.net/forums/showthread.php?t=1662422)) In this way, the ignition module is synchronized to the engine (TDC) so that it can effectively calculate the proper time to fire the spark plug BEFORE TDC.+The Nosecone Ignition unit (98-03 not-S) can be **statically** timed (without the engine running) using the built-in LED. The procedure is to manually rotate the engine (bike on lift, 5th gear, rotate rear tire to rotate engine) to position the engine to TDC (front cylinder compression stroke) using the timing hole to look for & center the vertical line. Then, turn the ICM/Cam Sensor Plate slightly clockwise & counterclockwise to find the exact spot where the light switches between on & off - Lock down the plate.((aswracing comments https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/154902-sportster-timing?t=1662422)) In this way, the ignition module is synchronized to the engine (TDC) so that it can effectively calculate the proper time to fire the spark plug BEFORE TDC.
  
 **Static TDC Timing for the 1998-2003 Sport Model**\\ **Static TDC Timing for the 1998-2003 Sport Model**\\
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 **Setting the Dynamic Timing**\\ **Setting the Dynamic Timing**\\
-To set the timing **dynamically**, with the engine operating, first, remove the timing plug & install the clear timing hole viewer plug (It MUST NOT touch the flywheel but needs to be as close as possible). Connect the clamp of an inductive pickup timing light (powered by the battery) to the front spark plug wire. This will allow you to 'shoot the light' into/thru the clear viewer plug. Then start the engine, set the idle at 1000 RPMs & shoot the light into the timing hole. Move the timing plate so that the 20° advance timing mark shows up in the center of the timing hole. For 01-03 1200S models, estimate the specified 15° BTDC at 1000RPMs based on the 20° flywheel mark, using the tick marks on the Cam Sensor Plate as a guide or use a dial back timing light.+To set the timing **dynamically**, with the engine operating, first, remove the timing plug & install the clear timing hole viewer plug (It MUST NOT touch the flywheel but needs to be as close as possible). Connect the clamp of an inductive pickup timing light (powered by the battery) to the front spark plug wire. This will allow you to 'shoot the light' into/thru the clear viewer plug. Then start the engine, set the idle for 1986-1995 models at 1800RPMs (40° timing - single dot) or set the idle for 1996-2003 models at 1000 RPMs (20° timing - double dots). Then shoot the light into the timing hole. Move the timing plate so that the proper advance timing mark shows up in the center of the timing hole. For 01-03 1200S models, estimate the specified 15° BTDC at 1000RPMs based on the 20° flywheel mark, using the tick marks on the Cam Sensor Plate as a guide or use a dial back timing light.
  
 \\ \\
 {{:techtalk:evo:engctl:camsensorplate.jpg?400|}} {{:techtalk:evo:engctl:camsensorplate.jpg?400|}}
  
-**Moving the Cam Sensor Plate Clockwise (CW) will increase the Advance Before TDC. Moving the plate Counterclockwise (CCW) will retard (or reduce) the Advance Before TDC. TAKE NOTE that each timing mark on the plate (long-to-short) is equal to changing the ignition timing by about 5°. Move the plate __VERY LITTLE__ to make adjustments.** ((aswracing post#17 at http://xlforum.net/forums/showthread.php?t=488663))+**Moving the Cam Sensor Plate Clockwise (CW) will increase the Advance Before TDC. Moving the plate Counterclockwise (CCW) will retard (or reduce) the Advance Before TDC. TAKE NOTE that each timing mark on the plate (long-to-short) is equal to changing the ignition timing by about 5°. Move the plate __VERY LITTLE__ to make adjustments.** ((aswracing post#17 at https://www.xlforum.net/forum/sportster-motorcycle-buell-motorcycle-forum-general-discussion/dyno-charts-and-result/71505-help-me-diagnose-my-dyno-tune?t=488663)) 
 + 
 +The Cam Sensor Plate can be rotated slightly to accomodate getting the timing mark in the center of the timing hole. You can also move the plate to change the base timing (thus moving both curve sets wholly up or down in all rpm ranges) by setting the timing to a few degrees more or less than the specified advance timing mark. For 1991-later models (right side window), you should be able to see the timing mark move to the right edge of the hole (more advanced) or the left edge of the hole (less advanced). You might find that a Timing Light with a Dial Back feature allows you to set a specific alternate timing setting using the TDC mark as a reference. 
 + 
 +Some dial back timing lights have trouble working with the odd timing signals from a dual-spark 45° engine.
  
-The Cam Sensor Plate can be rotated slightly to accomodate getting the timing mark in the center of the timing hole. You can also move the plate to change the base timing (thus moving both curve sets wholly up or down in all rpm ranges) by setting the timing (at 1000 RPMs) to a few degrees more or less than the specified advance timing mark. You should be able to see the timing mark move to the right edge of the hole (more advanced) or the left edge of the hole (less advanced). You might find that a Timing Light with a Dial Back feature allows you to set a specific alternate timing setting, but some of these dial back lights have trouble working with the odd timing signals from a dual-spark 45° engine.+Adding more advance will increase the likelihood of pinging when the engine is hot and/or under heavy acceleration. It is not recommended to move the timing more than an absolute total of 10° either way from the recommended timing. That's only two tick marks!
  
-Adding more advance will increase the likelihood of pinging when the engine is hot and/or under heavy acceleration. It is not recommended to move the timing (from 20°BTDC) more than an absolute total of 10° either way. That's only two tick marks!+If you need more change in the timing for your engine, an aftermarket ignition with adjustable advance curves may be required.
  
-More Information Here: +More Information on timing is Here: 
-http://xlforum.net/forums/showthread.php?threadid=2008019+https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/188579-timing-on-883-to-1200-conversion?threadid=2008019
  
 {{:techtalk:evo:engctl:96-03-timing-marks.jpg?400|}}{{:common:space100x5px.jpg?50|}} {{:techtalk:evo:engctl:96-03-timing-marks.jpg?400|}}{{:common:space100x5px.jpg?50|}}
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   * **Additional References:**    * **Additional References:** 
     *For the sake of not repeating what can be looked up directly, the following links have VOES discussions (as well as other info).     *For the sake of not repeating what can be looked up directly, the following links have VOES discussions (as well as other info).
-      *http://xlforum.net/forums/showthread.php?t=5945 +      *https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/3868-voes-adjusting?t=5945 
-      *http://xlforum.net/forums/showthread.php?t=594019 - Thread not all VOES related\\+      *https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/80961-my-1st-h-d-please-help-with-issues?t=594019 - Thread not all VOES related\\
       *These posts from the above thread are most applicable:       *These posts from the above thread are most applicable:
-      * . . http://xlforum.net/forums/showpost.php?p=2210315&postcount=173 +      * . . https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/80961-my-1st-h-d-please-help-with-issues/page12?postcount=173#post1716395 
-      * . . http://xlforum.net/forums/showpost.php?p=2210326&postcount=174 +      * . . https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/80961-my-1st-h-d-please-help-with-issues/page12?postcount=174#post1716405 
-      * . . http://xlforum.net/forums/showpost.php?p=2210400&postcount=180 +      * . . https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/80961-my-1st-h-d-please-help-with-issues/page12?postcount=180#post1716472 
-      *This post has some great pictures of the inside of the VOES: +      *This post has some great pictures of the inside of the VOES: [[techtalk:evo:elec01a|SubDoc - Dissecting the Voes]] 
-      * . . http://xlforum.net/forums/showpost.php?p=2210349&postcount=175+      * . . https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/80961-my-1st-h-d-please-help-with-issues/page12?postcount=175#post1716427
       *http://www.mklsportster.com/xlvoes.htm       *http://www.mklsportster.com/xlvoes.htm
       *http://www.wildwestcycle.com/f_voes.html       *http://www.wildwestcycle.com/f_voes.html
  
-((Most of the above information comes from an article by IXL2Relax of the XLFORUM.net http://xlforum.net/forums/showthread.php?t=1863153))+((Most of the above information comes from an article by IXL2Relax of the XLFORUM.net https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/173626-voes-its-operation-adjustment?t=1863153))
  
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- 
- 
  
 ===== Ignition Coil Design ===== ===== Ignition Coil Design =====
-((Updated by IXL2Relax - includes parts from SportsterDoc's post on the XLForum - http://xlforum.net/forums/showthread.php?t=1780092))+((Updated by IXL2Relax - includes parts from SportsterDoc's post on the XLForum - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/165501-coil-testing?t=1780092))
  
 **How-it-works by Steelworker:** An ignition coil is a pulse-type transformer, consisting of a low voltage primary winding (the input) and a high voltage secondary (output) winding, wrapped around a laminated iron core. The primary circuit is completed by the points or electronic ignition module closing the primary circuit to ground. The flow of current in the primary windings induces a strong magnetic field in the laminated iron core. When the primary circuit is broken (by the ground being removed), the strong magnetic field in the core collapses suddenly, which induces a high voltage electrical discharge out of the secondary circuit, thereby, producing a spark strong enough to bridge the electrode gap of each spark plug. **How-it-works by Steelworker:** An ignition coil is a pulse-type transformer, consisting of a low voltage primary winding (the input) and a high voltage secondary (output) winding, wrapped around a laminated iron core. The primary circuit is completed by the points or electronic ignition module closing the primary circuit to ground. The flow of current in the primary windings induces a strong magnetic field in the laminated iron core. When the primary circuit is broken (by the ground being removed), the strong magnetic field in the core collapses suddenly, which induces a high voltage electrical discharge out of the secondary circuit, thereby, producing a spark strong enough to bridge the electrode gap of each spark plug.
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 {{:techtalk:evo:engctl:coil-singlefirewiring-07-later.jpg?400|}}\\ {{:techtalk:evo:engctl:coil-singlefirewiring-07-later.jpg?400|}}\\
 See this thread regarding Knock Sensing in 2014+ models\\ See this thread regarding Knock Sensing in 2014+ models\\
-- http://xlforum.net/forums/showthread.php?threadid=2040499\\+- https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/191218-do-2014-sportsters-have-spark-knock-control?threadid=2040499\\
  
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 2004-later (or 98-03 1200S): On connectorized, single-fire coils, be sure any modified wiring matches the connections and polarity specified in the schematics. 2004-later (or 98-03 1200S): On connectorized, single-fire coils, be sure any modified wiring matches the connections and polarity specified in the schematics.
  
-See this excellent [[http://xlforum.net/forums/showthread.php?t=666142|__XLForum Thread__]], especially Post#20 by Fe Head.+See this excellent [[https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/86179-does-coil-polarity-really-matter?t=666142|__XLForum Thread__]], especially Post#20 by Fe Head.
  
  
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 . . amount since it represents both coils in series. The doubled value is shown above.\\ . . amount since it represents both coils in series. The doubled value is shown above.\\
 From the manual, 04-06 model is listed as 5500-7500 ohms (for one secondary coil) From the manual, 04-06 model is listed as 5500-7500 ohms (for one secondary coil)
- ((http://xlforum.net/forums/showpost.php?p=5511178))\\+ ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/124047-getting-out-the-wrenches-was-broken-exhaust-stud/page32#post4055982))\\
 From the manual, 07-up model is listed as 1500-2400 ohms (for one secondary coil) From the manual, 07-up model is listed as 1500-2400 ohms (for one secondary coil)
- ((http://xlforum.net/forums/showpost.php?p=5438264)) + ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/185994-intermittent-miss-backfire-stalls-while-running#post5438264)) 
- ((http://xlforum.net/forums/showpost.php?p=4880302)) + ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/166003-possible-ignition-issues-with-my-1200-sportster-2008/page2#post3547245)) 
- ((http://xlforum.net/forums/showpost.php?p=3122008))\\+ ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/110527-bike-cranks-but-won-t-start-after-running-harness-through-frame/page2#post2334955))\\
  
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 ^ **On 2004-later models**, the ICM will not fire during engine turn over with both spark plugs removed. At least\\ one spark plug must be installed to create engine compression. **For simplicity**, for all 2004-later spark tests,\\ you can use a spare, known good, spark plug that is grounded to the engine fins. Connect the spark plug wire\\ under test to the spare spark plug rather than removing the original in-cylinder spark plug. ((NOTE from 2004 EDM: Engine will not spark with both spark plugs removed. When checking for spark, use SPARK TESTER (Part No. HD-26792) with both plugs installed.)) | ^ **On 2004-later models**, the ICM will not fire during engine turn over with both spark plugs removed. At least\\ one spark plug must be installed to create engine compression. **For simplicity**, for all 2004-later spark tests,\\ you can use a spare, known good, spark plug that is grounded to the engine fins. Connect the spark plug wire\\ under test to the spare spark plug rather than removing the original in-cylinder spark plug. ((NOTE from 2004 EDM: Engine will not spark with both spark plugs removed. When checking for spark, use SPARK TESTER (Part No. HD-26792) with both plugs installed.)) |
  
-**2004-2006** ((http://xlforum.net/forums/showpost.php?p=5309032&postcount=44))  \\+**2004-2006** ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/180786-engine-turns-over-but-it-wont-start/page3?postcount=44#post3864199))  \\
 Find the Ignition Control Module (ICM) under the seat - Remove the connector from the ICM (12 pin connector known as 10A/B). On that connector, Pin#5 (BLACK Wire) is connected to the main ground while Pin#6 (BLUE/Orange Wire - Front) and Pin#7 (YELLOW/Blue Wire - Rear) provide the triggers for the dual-coil. Find the Ignition Control Module (ICM) under the seat - Remove the connector from the ICM (12 pin connector known as 10A/B). On that connector, Pin#5 (BLACK Wire) is connected to the main ground while Pin#6 (BLUE/Orange Wire - Front) and Pin#7 (YELLOW/Blue Wire - Rear) provide the triggers for the dual-coil.
  
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 {{techtalk:evo:engctl:camsensorconnpins-evo1.jpg|}}((Illustration created by IXL2Relax at the XLForum)) {{techtalk:evo:engctl:camsensorconnpins-evo2.jpg|}}((Illustration created by IXL2Relax at the XLForum))\\ {{techtalk:evo:engctl:camsensorconnpins-evo1.jpg|}}((Illustration created by IXL2Relax at the XLForum)) {{techtalk:evo:engctl:camsensorconnpins-evo2.jpg|}}((Illustration created by IXL2Relax at the XLForum))\\
  
-(Note: the 1998-2003 Sport model uses the same CPS & Connector as the 1994-1997 models. The slotted rotor cup is different on the Sport models, having additional slots to allow for the single-fire ignition. Note also, with the new ICM module and the addition of a MAP Sensor, the power to the Cam Position Sensor is 5v (as to the MAP Sensor) for the 1998-2003 'S' models.)+(Note: the 1998-2003 Sport model uses the same CPS & Connector as the 1994-1997 models. The slotted rotor cup is different on the Sport models, having additional slots to allow for the single-fire ignition. Note also, with the new ICM module and the addition of a MAP Sensor, the power to the Cam Position Sensor is 5v (5v also to the MAP Sensor) for the 1998-2003 'S' models.)
  
 **Testing the ability of the ICM to sense the Cam Rotor & fire the Coil**\\ **Testing the ability of the ICM to sense the Cam Rotor & fire the Coil**\\
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 ^ Year Model ^ Use/Type HD Plug ^ Alt. Plug Brand/Number ^ Ignition Type Spark Gap ^ ^ ^ Year Model ^ Use/Type HD Plug ^ Alt. Plug Brand/Number ^ Ignition Type Spark Gap ^ ^
 |1986-2016 |HD 6R12 (resistor type)| Autolite 4164\\ Bosch YR6LDE\\ Champion RA8HC\\ NGK DCPR7E\\ Screamin Eagle EX12S\\ |Electronic Ign. 0.038-0.043"\\ \\ \\ 12mmX1.25mm Threads - 12-18 ftlbs torque\\ Wrench = 5/8" or 16mm ||    |1986-2016 |HD 6R12 (resistor type)| Autolite 4164\\ Bosch YR6LDE\\ Champion RA8HC\\ NGK DCPR7E\\ Screamin Eagle EX12S\\ |Electronic Ign. 0.038-0.043"\\ \\ \\ 12mmX1.25mm Threads - 12-18 ftlbs torque\\ Wrench = 5/8" or 16mm ||   
 +
 +
 +\\
 +
 +
 +===== FYI: Buell Ignition Modules =====
 +
 +Note: (From aswracing in [[https://www.xlforum.net/forum/buell-motorcycle-forum/buell-motorcycle-electrical-and-ignition/203594-buell-s1-m2-dyna-2000-7-pin-to-8-pin-wiring-schematic#post4558129|this post on the xlforum]])
 +
 +The Buell X1 was only made from 1999-2002. It is EFI based, with a single ECM (engine control module) that controls both spark and fueling. No separate ignition module at all. The same is true for all 1999-2002 Buell S3 models. The parts books refer to the ECM as a "control module".
 +
 +The 2001-2002 ignition module found on the M2 is an actual ignition module. Since the M2 is carbureted, the module provides control only of the spark advance but no control of fueling. Although it has a similar appearance to the ECM found on 1999-2002 X1 & S3 models, the part number is different and the parts books refer to it as an "ignition module". This 2001-2002 M2 ignition module is also a bastard, not found on any other Harley or Buell, and no aftermarket replacements available for it. The only high performance version of it I've ever seen was the Buell Pro-Series version which was offered back in the day. It's an issue when someone comes to us for a performance package for a 2001-2002 M2. We basically have to tell him to chuck it and wire in a nose cone module.
 +
 +The other carbureted Buell models (1995-1996 S2, 1996-1998 S1/S1W, 1997-2000 M2, and 1997-1998 S3) all came with 8-pin modules, except 49-state 1995 S2's, which came with 7-pin modules. These are similar to the XL version ignition modules.
 +
 +There's an adapter available to connect an 8-pin module to a 7-pin bike, and another one available to go the other direction, i.e. a 7-pin module to an 8-pin bike.
 +
  
  

Trace: • REF: Engine Mechanicals