Mallory Ignition 6867m, 6866m User Manual
OFF-ROAD
ELECTRONIC IGNITION CONTROL
FORM 1678M 05/07
INSTALLATION INSTRUCTIONS
1MALLORY IGNITION
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GENERAL INFORMATION
This ignition includes 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 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 altern a t o r, 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 a s
an electric fuel or water pump, increase the
amp/hour rating.
Coils
For optimum performance with your 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 d e s i g n e d
for use with OEM electronic ignitions.
NOTE: Do not use Mallory’s PROMASTER®
Coil P/N 28880.
Tachometers
The yellow wire on the 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
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 Ignition Control.
NOTE: Do not install the Ignition Control in
any vehicle that is originally equipped with a
CD ignition contro l .
Spark Plug Wires
High quality, spiral wound wire and proper
routing are essential to the operation of the
Ignition C o n t rol. 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 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 ord e r
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
c r o s s - f i r e , 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
The HyFire OFF-ROAD is completely
encapsulated to eliminate moisture intrusion
and to protect the ignition from vibration
and impact. The rotary switches are
moisture-resistant also. During installation,
no further consideration needs to be taken
except to mount the ignition away from heat
sources as discussed later in these
instructions.
Welding
To avoid any damage to the Ignition Control
when welding on the vehicle, disconnect the
positive (red) and negative (black) power
cables of the Ignition Control. It is also a
good idea to disconnect the tachometer
g r ound wire as well.
Distributor Cap and Rotor
We recommend installing a new distributor
cap and rotor when installing the 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.
OFF-ROAD Diagnostic LED
On the end panel of your 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
m i c r o p r ocessor is running pro p e r l y. 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 pro b l e m s . If the LED
flashes when the engine is cranked, but
there is still no spark, the problem lies
somewhere else.
MOUNTING
The 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
w i r es 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.
WIRING
Wire Length
All of the extension harness wires of the
Ignition Control may be shortened as long as
quality connectors are used or soldere d 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 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. N O TE: This is the only wire that makes
electrical contact with the coil positive
(+) terminal.
Black Connects to the negative (–) terminal of the
c o i l . N O TE: This is the only wire that makes
e l e c t r i c a l contact with the coil negative
(–) terminal.
Green Connects to points, electronic ignition
amplifier output or to the green wire of a
Mallory timing a c c e s s o ry. When this wire is
u s e d , the mag n e t i c pickup connector is not
used.
Additional Individual Wires:
Yellow Connects to the tachometer.
Trigger Wires
Either of two circuits will trigger the 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.
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 OFF-ROAD 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
Cylinder Selection
Your 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.
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
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