Mallory Ignition 6862m, 6863m User Manual

SPORT 6

ELECTRONIC IGNITION CONTROL

FORM 1662M 09/06

INSTALLATION INSTRUCTIONS

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GENERAL INFORMATION

Some SPORT 6 models include a single
stage RPM limiter. You can set various
settings using the switches that are located
in the end bracket. See Figure 1 of this
instruction form for more information about
the rev limiting and ignition retard features.

Battery

The SPORT 6 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 SPORT 6
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 designed
for use with OEM electronic ignitions.

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

Tachometers

The yellow wire on the SPORT 6 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
SPORT 6 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 5.

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. 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 SPORT 6 Ignition Control.

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

Spark Plug Wires

High quality, spiral wound wire and proper
routing are essential to the operation of the
SPORT 6 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 SPORT 6 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.

MISCELLANEOUS INFORMATION
Sealing

Do not attempt to seal the SPORT 6 Ignition
Control. All of the circuits of a SPORT 6
receive a conformal coating of sealant that
protects the electronics from moisture. Sealing
the SPORT 6 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 SPORT 6
Ignition Control when welding on the vehicle,
disconnect the positive (red) and negative
(black) power cables of the SPORT 6 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 SPORT 6
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.

SPORT 6 Diagnostic LED

On the end panel of your SPORT 6 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.

MOUNTING

The SPORT 6 Ignition Control can be
mounted in any position. If you mount it in
the engine compartment, keep it away from
moisture, 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. Mounting it horizontally or with the
wiring down is preferred.

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WIRING
Wire Length

All of the wires of the SPORT 6 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 SPORT 6
Ignition Control receives its main power
directly from the battery.

WIRE FUNCTIONS

Power Leads – 2 Pin Weatherproof
Connector

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 – 4 Pin
Weatherproof Connector

Red Connects to a switched 12 volt source,

such as the ignition key.

Yellow Connects to the positive (+) terminal of the

coil. NOTE: This is the only wire that makes

electrical contact with the coil positive
(+) terminal.

Black Connects to the negative (–) terminal of the

coil. NOTE: This is the only wire that makes

electrical contact with the coil negative
(–) terminal.

Green 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.

Additional Individual Wires:

Yellow Connects to the tachometer.

Trigger Wires

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

NOTE: The two circuits must never be
used together.

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.

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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

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 SPORT 6 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
SPORT 6 Cylinder Selection

Your SPORT 6 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 - 6863M only
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.

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
Chrysler Orange/White Black

FIGURE 1

3

3

2

2

4

4

1

5

5

0

6

6

9

7

7

8

8

LED

CYLINDER

SELECT

3

2

4

1

0

9

7

8

1

5

0

6

9

MAIN

RPM

LIMITER