Mallory Ignition 35496 User Manual
FORM 97140090
INSTALLATION INSTRUCTIONS
Ignition Model #35496
CAUTION: CAREFULLY READ INSTRUCTIONS BEFORE PROCEEDING. NOT LEGAL FOR USE OR SALE ON POLLUTION CONTROLLED VECHICLES
OVERVIEW
ACCEL Ignition Model 35496 is intended for use with Harley-Davidson®
Evolution® type motorcycle engines. The Model 35496 replaces the original equipment (OE) electronic ignition system on 1978-99 models. The unit
mounts in the gear case cover and uses the standard H-D® timing rotor.
It can also be used on earlier models with breaker points and mechanical
advance.
The Model 35496 offers adjustable advance, adjustable RPM limit settings in 100 RPM increments, and switch selectable single or dual fire
modes. Single fire mode improves starting, reduces the occurrence of
backfiring at low RPM, and improves power at high RPM. A red status LED
flashes when the engine reaches top dead center (TDC) and allows easy
static timing. The status LED also provides diagnostic information. A green
VOES LED illuminates when the VOES (vacuum switch) input is active.
AVOIDING HEAT RELATED FAILURES
Heat kills electronics. The Model 35496 uses electronic devices rated
for operation at 105 deg C (221 deg F), the highest rating available. The unit
can tolerate somewhat higher temperatures, but exposure to temperatures above 125 deg C (257 deg F) will greatly reduce life expectancy. We
sometimes see problematic applications where several module failures
have occurred. The failure mode is a classic thermal intermittent where the
module stops firing one cylinder when it gets hot. We have found that these
problematic applications share one or more of the following characteristics:
INSTALLATION
1. Turn off the ignition switch and disconnect the battery
ground cable before proceeding.
• VOES switch removed or non-functional. All street driven engines
require vacuum advance. Without vacuum advance at idle and part
throttle, thermodynamic efficiency is reduced and engine temperatures
increase significantly.
• Improper carburetor jetting resulting in lean air/fuel ratio (AFR). A lean
AFR will cause the engine to run very hot. All performance engine
modifications necessitate carburetor rejetting. Carburetors are never
correctly jetted out-of-the-box. The only practical means of correctly jetting a carburetor is to test the motorcycle on a chassis dyno
equipped with an exhaust gas sniffer.
• Lack of an oil cooler on a 95 CID or larger engine.
• Exhaust pipe without heat shield in close proximity to the nose cone. If
any of the above applies to your application, the Model 35496 may be
exposed to excessive temperatures resulting in reduced life expectancy. Use an infrared thermometer to check the module temperature.
INCLUDED AND ADDITIONAL REQUIRED PARTS
All units include a parts bag with crimp terminals for coil and VOES
hookup.
FL series Big-Twin® models manufactured prior to 1985, FX series BigTwin® and XL Series Sportster® models manufactured prior to 1984, all
Sportster® 1200S models, and all models with original equipment breaker
points will require H-D® timing rotor P/N 32402-83 or an equivalent aftermarket part.
2. Refer to Figure 1. Remove gear case cover plate and mounting hardware. You may have to drill out two rivets that hold
the cover (reassemble with supplied self-threading screws).
Remove the sensor plate or breaker points. Make sure that
the correct H-D® P/N 32402-83 timing rotor is installed.
3. You can completely remove the OE ignition harness and
external module (1980 and later models) if desired. However,
you must disconnect all OE wires from the coil except the
white/black wire from the engine stop/run switch.
4. Install the Model 35496 unit. Wrap one turn of electrical tape
around the end of the protective wire harness sleeve. This will
compress the sleeve and allow you to easily feed it through
the cable exit hole in the gear case cover. The tape will also
keep the sleeve end from fraying. You will have to enlarge the
hole with a drill on early models and some Sportsters®.
5. Rotate the unit and then place it into position as shown in
Figure 2. Be careful to avoid damage to the black plastic Hall
Effect sensors on the bottom of the unit.
6. Route the wiring harness along the side of the unit and install the
mounting standoffs as shown in Figure 3A for Big Twin or 3B for
Sportster® models. Do not fully tighten the standoffs or install
the outer cover plate until after the static timing procedure.
Figure 1 - Feeding Harness Through Exit Hole
ACCEL IGNITION www.accel-ignition.com
1
Figure 2 - Installing Unit (Note Orientation)
7. Route the wire harness along the frame tubing to the ignition coil.
Make sure that the harness is clear of hot exhaust areas and cannot
chafe against sharp edges. Secure the harness with nylon cable ties.
8. Refer to the appropriate wiring diagram. Use the dual fire hookup
shown in Figure 4 if you have an OE coil or other coil with two primary
terminals. Use the single fire hookup in Figure 5 if you are installing
an aftermarket coil with three primary terminals. Use appropriate
crimp terminals for coil and VOES hookup. With the exception of the
tachometer and rear coil section (single fire only), standard H-D®
wire color codes are used. Tape up any unused wires.
9. Install the supplied Weather Pack connector set on the brown
tachometer wire as shown. If a tachometer is not used, seal the end
of the mating plug with silicone RTV and use it as a protective cover.
Use a proper Weather Pack crimping tool or solder the terminals.
10. Single Fire Tach Hookup. If your motorcycle had a tach before installation of the ACCEL module, the tach was connected to the pink coil
wire. When you connect the tach direct to the ACCEL module as
shown in Figure 5 for a single fire application, you must make sure
that it is not still connected to the pink coil wire. Trace the wire going
all the way back to the tach to avoid an inadvertent coil connection.
NOTE: The unit is grounded by means of the gear case
housing. The mounting surface must not be anodized or
painted.
Figure 3A - Finished Big-Twin® Installation
11. Reconnect the battery ground cable. Complete the setup and timing
procedures given on pages 3-7.
12. Reinstall the cover plate using two supplied 10-24 x 1/4” socket head
screws and lock washers in place of the original rivets. You will have
to tap the rivet holes on the inner plate (do this with the plate removed
from the bike to avoid damaging the ignition). You can use the supplied 10-24 x 3/8” self threading screw as a tap.
Figure 3B - Finished Sportster® Installation
CAUTION: Engine damage from excessive timing advance may result if the purple/white VOES wire is
inadvertently shorted to ground.
2
www.accel-ignition.com ACCEL IGNITION
OPERATING MODES
A single 10 position rotary switch is used to select the operating mode.
Switch settings are as follows:
0 Street advance curves, dual fire, multi-spark disabled
1 Street advance curves, dual fire, multi-spark enabled
2 Street advance curves, single fire, multi-spark disabled
3 Street advance curves, single fire, multi-spark enabled
4 Race advance curves, dual fire, multi-spark disabled
5 Race advance curves, dual fire, multi-spark enabled
6 Race advance curves, single fire, multi-spark disabled
7 Race advance curves, single fire, multi-spark enabled
8 Not used
9 Race advance curves, single fire, kick start
The engine will not run if the mode switch setting does not match the
wiring hookup (i.e. you cannot select single fire mode with a dual fire coil
hookup).
Advance curve families are shown in Figures 6 and 7. Use the street
advance curves (mode switch settings 0-3) for stock or mildly modified
engines. Use the race advance curves (mode switch settings 4-7) for high
compression engines.
We recommend that you enable multi-spark. When multi-spark is
enabled, a continuous series of sparks is fired from the advanced timing
point until TDC. Most air-cooled engines require relatively cold spark plugs
to prevent detonation under high load. Multi-spark reduces the consequent
tendency for plug fouling at idle.
Switch setting 9 selects race advance curves, single fire, and kick start
mode. Multi spark is disabled.
Figure 4 - Dual Fire Wiring Diagram
ACCEL IGNITION www.accel-ignition.com
3
Loading...