Mallory Ignition 6861m User Manual

1MALLORY IGNITION www.malloryracing.com

HYFIRE®6AL2

ELECTRONIC IGNITION CONTROL

PART NO 6861M

INSTALLATION INSTRUCTIONS

FORM 1643

GENERAL INFORMATION

The HYFIRE®6AL2 includes a two stage RPM limiter. You can set
various RPM limits using the switches that are located in the end
bracket. See Figure 1 of this instruction form for more information
about the rev limiting features.

Battery

The HYFIRE

®

6AL2 Ignition Control operates on any negative ground,
12 volt electrical system with a distributor. It will also work with 16
volt batteries and can withstand a momentary spike of 24 volts in
case of jump starts. This system delivers full voltage with a supply of
10-18 volts, and operates with a supply voltage as low as 8 volts.

If your application does not use an alternator, allow at least 15
amp/hours for every half hour of operation. If you crank the engine
with the same battery or other accessories, such as an
electric fuel or water pump, increase the amp/hour rating.

Coils

For optimum performance with your HYFIRE®6AL2 Ignition Control,
we recommend a Mallory PROMASTER®Coil P/N 29440 or 30440
or 30441 Mallory PROMASTER®E. For continuous high RPM use,
coil part numbers 29625, 30625 or 30626 can also be used. You
may also use most stock coils or aftermarket coils designed as
stock replacements.

NOTE: Do not use Mallory’s PROMASTER®Coil P/N 28880.

Tachometers

The yellow wire on the HYFIRE®6AL2 Ignition Control provides a
trigger signal for tachometers, shift lights, or other add-on RPM
activated devices. This wire produces a 12 volts square wave signal
with a 20% duty cycle.

Some vehicles with factory tachometers may require a tach adapter
to work with the HYFIRE®6AL2 Ignition Control. If your GM vehicle
uses an inline filter, it may cause the tach to drop to zero on
acceleration. If this occurs, bypass the filter. For more information
on tachometers, see page 4.

Spark Plugs

Using the correct spark plug and heat range is important for
optimum performance. Because there are so many variables to
consider, we suggest starting with your engine manufacturer’s
spark plug recommendation. From there, you can experiment with
small changes in plug gap and heat range to obtain the best
performance from your engine. Use the chart at right as a starting
point. We also recommend non-resistor spark plugs.

Foreign Vehicles

Because of modern fuel injection systems, some foreign vehicles
may require a tachometer/fuel injection adapter to work with the
HYFIRE

®

6AL2 Ignition Control.

NOTE: Do not install the HYFIRE®6AL2 Ignition Control in any
vehicle that is originally equipped with a CD ignition control.

Spark Plugs and Wires

High quality, spiral wound wire and proper routing are essential to
the operation of the HYFIRE®6AL2 Ignition Control. This type of wire
provides a good path for the spark to follow while minimizing
electromagnetic interference (EMI).

NOTE: Do not use solid core spark plug wires with the HYFIRE

®

6AL2 Ignition Control.

Routing

Wires should be routed away from sharp edges, moving objects,
and heat sources. Wires that are next to each other in the engine’s
firing order should be separated. For example, in a Chevy V8 with a
firing order of 1-8-4-3-6-5-7-2, the #5 and #7 cylinders are
positioned next to each other on the engine as well as in the firing
order. Voltage from the #5 wire could jump to the #7 wire. This
could cause detonation and engine damage.

For added protection against cross-fire, Mallory offers PRO SHIELD
insulated sleeving. Pro Shield is a glass woven, silicone coated
protective sleeve that slides over your plug wires. It also helps
reduce damage from heat and sharp objects.

1 HYFIRE

®

6AL2 Ignition Control
4 #10 Sheet Metal Screws
2 Wire Ties
2 Ring Terminals, Insulated
1 1-amp/100 volt Diode
2 1/4" Tab Terminals

5 1/4" Male Disconnects
5 1/4" Female Disconnects
1 Rubber Grommet
2 Cable Clamps
1 Magnetic Pickup Extension

PARTS INCLUDED:

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Rotary Switch Position Examples

Switch #1 Switch #2 RPM Limit

1 0 1,000
2 4 2,400
2 5 2,500
6 0 6,000
7 8 7,800
9 9 9,900

Auxiliary RPM Limiter

The Auxiliary RPM Limiter is adjusted using the pair of rotary
switches on the right side of the end plate. They are adjusted the
same as the Main RPM Limiter, the left switch of the pair is used to
adjust the 1,000’s and the right switch of the pair adjusts the 100’s.

MOUNTING

The HYFIRE®6AL2 Ignition Control can be mounted in any
position. If you mount it in the engine compartment, keep it away
from moving objects and heat sources. Do not mount the unit in
an enclosed area, such as the glove box. When you find a suitable
location to mount the unit, make sure all wires of the ignition
reach their connections. Hold the ignition in place and mark the
location of the mounting holes. Use a 1/8" drill bit to drill the
holes. Use the supplied self-tapping screws to mount the box.

WIRING

Wire Length

All of the wires of the HYFIRE®6AL2 Ignition Control may be
shortened as long as quality connectors are used or soldered in
place. To lengthen the wires, use one size larger gauge wire
(12 gauge for power leads, 16 gauge for all others). Use the
proper connectors to terminate all wires. All connections must be
soldered and sealed.

Grounds

A poor ground connection can cause many frustrating problems.
When a wire is specified to go to ground, connect it to the chassis.
Always connect a ground strap between the engine and chassis.
Connect any ground wires to a clean, paint-free metal surface.

Ballast Resistor

If your vehicle has a ballast resistor in line with the coil wiring, it
is not necessary to bypass it. This is because the HYFIRE®6AL2
Ignition Control receives its main power
directly from the battery.

MISCELLANEOUS INFORMATION

Sealing

Do not attempt to seal the HYFIRE®6AL2 Ignition Control. All of
the circuits of a HYFIRE®6AL2 receive a conformal coating of
sealant that protects the electronics from moisture. Sealing the
HYFIRE®6AL2 will not allow any moisture that seeps in through
the grommets to drain and may result in corrosion.

Welding

To avoid any damage to the HYFIRE®6AL2 Ignition Control when
welding on the vehicle, disconnect the positive (red) and negative
(black) power cables of the HYFIRE®6AL2 Ignition Control. It is
also a good idea to disconnect the tachometer ground wire as well.

Distributor Cap and Rotor

We recommend installing a new distributor cap and rotor when
installing the HYFIRE®6AL2 Ignition Control. Be sure the cap is
clean inside and out, especially the terminals and rotor tip. On
vehicles with smaller caps, it is possible for the air inside the cap to
become electrically charged causing crossfire which can result in
misfire. You can prevent this by drilling a couple of vent holes in the
cap. Drill the holes between terminals at rotor height, facing away
from the intake. If needed, place a small piece of screen over the
holes to act as a filter.

HYFIRE®6AL2 Diagnostic LED

On the end panel of your HYFIRE®6AL2 ignition there is a small
hole. Behind this hole is a red LED indicator. This serves two
purposes: when you first turn on the ignition switch, the LED will
flash rapidly 3 times. This indicates that the ignition system has
power, and that the microprocessor is running properly. In
addition, the LED will flash when receiving a proper trigger signal
from the vehicle. If, after a normal power-up, the LED doesn’t
flash when cranking the engine, you should check your triggering
circuit for problems. If the LED flashes when the engine is cranked,
but there is still no spark, the problem lies somewhere else.

HYFIRE®6AL2 Cylinder Selection

Your HYFIRE®6AL2 Ignition comes from the factory set up for 8
cylinder operation. If you want to use this ignition with a 4 or 6
cylinder engine, rotate the center rotary switch, accessible
through the end plate, to the proper number of cylinders. To
select the 4 cylinder mode, turn the switch to the “4” position.
See Figure 1.

RPM LIMITER SETTINGS

Main RPM Limiter

The main RPM Limiter is adjusted by using the pair
of switches on the left side of the end plate. The left
switch of the pair is for 1,000’s and right is for 100’s.
To eliminate the RPM Limiter, simply rotate the switches
to a setting above the engine’s maximum RPM.
See Figure 1.

FIGURE 1

MAIN

RPM

LIMITER

3

2

1

0

9

7

8

CYLINDER

SELECT

AUX

3

2

4

1

5

0

6

9

7

8

3

2

4

6

4

1

5

5

0

6

9

7

8

3

2

1

0

9

8

3

2

4

4

1

5

5

0

6

6

9

7

7

8

LED

RPM

LIMITER

3MALLORY IGNITION www.malloryracing.com

FROM HYFIRE® VIA

WHITE BLACK

USING THE MAGNETIC
PICKUP WIRE TO TRIGGER
THE HYFIRE® VIA

USING THE WHITE
WIRE TO TRIGGER
THE HYFIRE

®

VIA

CONNECTS TO

PURPLE

BLACK

MAGNETIC PICKUP

PURPLE

GREEN

COMMON COLORS FOR MAG PICKUP WIRES

Distributor Mag + Mag –

Mallory Crank Trigger Purple Green
Mallory Billet Competition Distributor,
Series Nos. 81 and 84 Orange Purple
Mallory COMP®9000 Series Nos. 96-99

Orange Purple
Mallory Harness P/N 29040 Red Black
MSD Orange/Black Violet/Black
MSD Crank Trigger Orange/Black Violet/Black
Ford Orange Purple
ACCEL 46/48000 Series Orange/Black Violet/Black
ACCEL 51/61000 Series Red Black
Chrysler Orange/White Black

WIRE FUNCTIONS

Power Leads

(enclosed in 6” of black shrink tubing)

The two heavy gauge wires (14 gauge) that deliver battery voltage
to the ignition:

Heavy Red Connects directly to the battery positive (+)

terminal or to a positive battery junction. It could
also be connected to the positive side of the
starter solenoid.

NOTE: Never connect this wire

to the alternator.

Heavy Black Connects to frame or chassis ground.

Trigger and Coil Leads

Small Red Connects to a switched 12 volt source, such as

the ignition key.

Orange Connects to the positive (+) terminal of the coil.

NOTE: This is the only wire that makes
electrical contact with the coil positive (+)
terminal.

Small Black Connects to the negative (–) terminal of the coil

NOTE: This is the only wire that makes
electrical contact with the coil negative (–)
terminal.

Trigger Wires

Either of two circuits will trigger the HYFIRE®6AL2 Ignition Control: a
points circuit (white wire) or a magnetic pickup circuit (violet and
green wires).

NOTE: The two circuits will never be used together.

White Connects to points, electronic ignition amplifier

output or to the green wire of a Mallory timing
accessory. When this wire is used, the magnetic
pickup connector is not used.

Violet/Green These wires are routed together in one harness

to form the magnetic pickup connector. The
connector plugs directly into a Mallory distributor
or crank trigger. It will also connect to factory
magnetic pickups or other aftermarket pickups.
The violet wire is positive (+) and the green is
negative (–). When these wires are used, the white
wire is not used. Consult the chart that shows the
polarity of other common magnetic pickups.

Yellow Connects to the tachometer.

Blue This wire is used to activate the Auxiliary (Staging)

RPM Limiter. It is activated by applying 12 volts to
the wire.

ROUTING WIRES

Route all wires away from heat sources, sharp edges, and moving
objects. Route the trigger wires separate from the other wires and
spark plug wires. If possible, route them along a ground plane, such
as the block or firewall, which creates an electrical shield. The
magnetic pickup wires should be routed separately and twisted
together to help reduce extraneous interference.

WARNING: The HYFIRE®6AL2 Ignition Control is a
capacitive discharge ignition. High voltage is
present at the coil primary terminals. Do not touch
these terminals or connect test equipment to them.

PRESTART CHECKLIST

• The only wires connected to the coil terminals should be the
orange connected to coil positive (+) and black connected to
coil negative (–).

• The small red wire is connected to a switched 12 volts source,
such as the ignition key.

• Power leads are connected directly to the battery positive and
negative terminals.

• If you’re not using an alternator, the battery should be
connected and fully charged.

• The engine is equipped with at least one ground strap to
the chassis.

THEFT DETERRENT

The HYFIRE

®

6AL2 Ignition Control provides an easy way to install

a theft deterrent kill switch. See Figure 2.

White Wire Trigger

When using the white wire to trigger the HYFIRE

®

6AL2 Ignition
Control, install a switch to the white wire and the other side to
ground. When the white wire is grounded, the vehicle will crank
but will not start.

Magnetic Pickup Trigger

When using the mag pickup to trigger the HYFIRE

®

6AL2 Ignition
Control, install a switch across the magnetic pickup violet wire to
ground. When the violet wire is grounded, the vehicle will crank
but will not start.

FIGURE 2

FOR EARLY GM VEHICLES
ATTACH DIODE TO
#4 TERMINAL

FOR FORD VEHICLES

ATTACH DIODE TO

#1 TERMINAL

1A-100V DIODE

TO CHARGING LIGHT

SPLICE HERE

DELCOTRON
ALTERNATOR

1A-100V DIODE

TO CHARGING LIGHT

SPLICE HERE

SMALL RED

FROM HYFIRE

®

VIA

12 VOLT

IGNITION SWITCH

CHRYSLER DUAL

BALLAST RESISTOR

WHITE WIRE FROM
HYFIRE® VIA

FROM POINTS OR
AMPLIFIER

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TACHOMETER COMPATIBILITY LIST

Aftermarket White Wire Magnetic Trigger
Tachometer Trigger Connector

Autogage 29074 29078
Autometer — —
Ford Motorsport — —
Moroso — —
Stewart 29074 29078
S.W. & Bi Torx — —
Sun 29074 29078
VDO 8910 29078
AMC (Jeep) 29074 29078
Chrysler 29074 29078
Ford (Before 1976) 29074 29078
Ford (After 1976) 29074 29078
GM Bypass in-line Bypass in-line

filter filter

Imports 29074 29078

TROUBLESHOOTING

This section offers several tests and checks you can perform to ensure
proper installation and operation of the HYFIRE®6AL2 Ignition Control.
If you experience a problem with your HYFIRE®6AL2, first check for
proper installation and poor connections. You can eliminate many
problems by checking these items. If you have any questions
concerning your HYFIRE®6AL2 Ignition Control contact the Mallory
Technical Service Department at 216-688-8300, option 5.

Tach/Fuel Adapters

If your tachometer does not operate correctly, you probably need a
Mallory tach adapter. Consult the Tachometer Compatibility List at right
for common tachometers and compatible tach adapters.

No-Run on Foreign Vehicles

Some foreign vehicles with fuel injection systems may require a
tachometer/fuel injection adapter to run with the HYFIRE

®

6AL2
Ignition Control. Often, the same trigger source is used to operate an
ignition, tachometer, and fuel injection. This results in a voltage signal
that is too low to trigger the fuel injection. A tach/fuel injection adapter
will usually solve this problem.

Inoperative Tachometers

If your tachometer fails to operate with the HYFIRE

®

6AL2 installed,
you may need a Mallory tach adapter. Before purchasing a tach
adapter, try connecting your tachometer trigger wire to the yellow wire
of the HYFIRE®6AL2 Ignition Control. This output produces a 12 volt,
square wave. If the tach still does not operate, you will need a tach
adapter.Two different tach adapters are available:

PN 29078 If you are using the magnetic pickup connector (green

and violet wires) to trigger the HYFIRE®6AL2, you will
need this adapter.

PN 29074 If your tach was triggered from the coil negative

terminal (voltage trigger) and you are suing the white
wire to trigger the HYFIRE®6AL2, you will need this
adapter.

Ballast Resistor

If you have a current trigger tach (originally connected to coil (+)
positive) and use the white wire of the HYFIRE

®

6AL2 for triggering,
you can purchase a Chrysler Dual Ballast Resistor (1973-76
applications). Wire it as shown in Figure 3.

Engine Run-On

If your engine continues to run even when the ignition is turned off,
you are experiencing engine run-on. Usually, older vehicles with an
external voltage regulator are susceptible to this condition. Because
the HYFIRE

®

6AL2 Ignition Control receives power directly from the
battery, it does not require much current to keep the unit energized.
If you are experiencing run-on, it is due to a small amount of voltage
going through the charging lamp indicator and feeding the small red
wire (even if the key is turned off).

GM 1973-83 with Delcotron Alternators

GM Delcotron alternators use an internal voltage regulator. Install the
diode inline on the smallest wire exiting the alternator (see Figure 5).
It is usually a brown wire.

Most other applications: To eliminate run-on, place a resistor in-line to
the HYFIRE

®

6AL2 small red wire to keep voltage from leaking into the

HYFIRE®6AL2 Ignition.

FIGURE 3

Early Ford and GM: To solve the run-on problem, a diode is supplied
with the HYFIRE® 6AL2 Ignition Control. By installing this diode in-line
of the wire that goes to the charging indicator, the voltage is blocked
from entering the HYFIRE®6AL2 Ignition Control. Figure 4 shows the
proper diode installation for early Ford and GM vehicles.

NOTE: Diodes are used to allow voltage to flow only one way.
Make sure the diode is installed facing the proper direction, as
shown in Figure 4.

Ford: Install the diode inline to the wire going to the #1 terminal.
GM: Install the diode inline to the wire going to the #4 terminal.

FIGURE 4

FIGURE 5