Installation Instructions for HI-4N MOTORCYCLE · PDF file6/12 1 9000-6100 Installation...

6/12 9000-6100111

Installation Instructions forHI-4N MOTORCYCLE IGNITION

For more information, see www.cranecams.comCAUTION: READ INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.

INTRODUCTION TheHI-4NignitionsystemisintendedforusewithHarley-David-son® motorcycles. The HI-4N replaces the original equipment(OE)electronicignitionsystemon1978andlatermodelsaswellasthepointsandmechanicaladvanceonearlymodels.Willnotworkin2000–2003Sportster®.

TheHI-4Nfeaturesstate-of-the-arttechnologythatallowsadjustableadvanceandrevlimit.AtimingLEDindicatesstatictiming(topdeadcenter)andgivesdiagnostic information.Twostartingmodesareprovided:electricstartandkickstart.Atachoutputgivesaccuratetachreadingsevenattherevlimit.

ADDITIONAL REQUIRED PARTS FX series Big Twin® and XL series Sportster® models prior to1984,FLseriesBigTwin®modelspriorto1985,andallmodelswithOEpointswill requireOE timing rotorP/N32402-83.Thispart isnot includedwiththeHI-4Ninstallationkitandcanbepurchasedseparately,CraneCamsPartNumber8-1150.

COIL AND SPARK PLUG CABLE CONSIDERATIONS Werecommendreplacing theOEcoil.Coilsusedwith theHI-4Nmusthaveat least2ohmsprimaryresistance.Coilswith4ohmsorhighermaybeused,butmaynotproduceoptimumoutput.Werecommendthefollowingcoilsforsingleanddual-plugapplications:

HI-4N Ignition With Single Plug Heads. UseCraneCamsP/N8-3005coil,whichwillfitinthestockmountinglocationonmostH-D®motorcycles.Youcanalsousetwodualsparktowercoilsandgroundoneofthetowersoneachcoiltotheenginecaseorframe.Youwillhavetofabricateabrackettomountthesecondcoil.

HI-4N Ignition With Dual Plug Heads. UsetwoCrane8-3006coils.Youwillhavetofabricateabrackettomountthesecondcoil.

CraneFireWirespiralcorewiresarerecommendedformaximumperformance.Donotusesolidcoppersparkplugcables;theymaycauseinterferencewithyourignitionsystemandaccessories.

REMOVAL OF POINTS IGNITION — EARLY MODELS PRIOR TO 1978 1.Turn ignitionswitchoffanddisconnectbatterygroundcable.DisconnectwiregoingfrombreakerpointstoCoil–(negative)terminal.

2.Refer to Figure 1.Remove ignition cover plate, gasket, andhardware(items1-3).Savetheseitemsforlaterre-use.

3.Notelocationofbreakerplate.ThereisaVnotchinthebreakerplateused foralignment.Whenyou install theHI-4N,align theVnotch in thesame location.This should set the timingcloseenoughtostarttheengine.Removeandsavethetwostandoffsandwashers (items4-5).Remove thebreakerplateassembly,wiring,cam,andadvanceassembly(items6–10).

REMOVAL OF OE ELECTRONIC IGNITION SYSTEM—1978 AND 1979 MODELS 1.Turnignitionswitchoffanddisconnectbatterygroundcable.

2.RefertoFigure2.Disconnectwiresgoingfromignitionmodule(item3)tocoil(14).

3.Removeignitioncoverplateandhardware(items1and2).Savetheseitemsforlaterre-use.Removeignitionmodule(3).

4.Notelocationoftimerplate(10).ThereisaVnotchinthetimerplateused foralignment.Whenyou install theHI-4N,align theVnotch in thesame location.This should set the timingcloseenoughtostarttheengine.Removeandsavethetwostandoffsandwashers(items4-5).Removethesensor,shield,timerplate,triggerrotor,andadvanceassembly(items6-12).

REMOVAL OF OE ELECTRONIC IGNITION SYSTEM—1980 AND LATER MODELS 1.Turnignitionswitchoffanddisconnectbatterygroundcable.

2.RefertoFigure3.RemoveOEignitionmoduleandwireharness(items1-4).Youwilldisconnecttwowiresatthecoil,wiregoingtotheVOES(VacuumOperatedElectricalSwitch),groundwireatthemodule,andthe3pinplug(20)thatconnectstothesensorplate.Refertoshopmanualforlocations.

3.Removeignitioncoverplatesandgasket(items5-9).Thiswillrequiredrillingouttworivets.Therivetswill laterbereplacedwithtwosuppliedselfthreadingscrews.

4.Inordertoremovethesensorplatecable,thecableplug(20)mustberemovedfirst.Useneedlenoseplierstopullthetermi-nalsoutoftheplug.Thenpullthecablethroughtheexitholeatthebottomofthetimingcover.

5.Notelocationofsensorplate(11).ThereisaVnotchinthesensorplateusedforalignment.WhenyouinstalltheHI-4N,youshouldaligntheVnotchinthesamelocation.Thisshouldsetthetimingcloseenoughtostarttheengine.Removeandsavethetwostand-offsandwashers(10).Removethesensorplate(item11).

WARNING: 1996 and later models have a vehicle tilt sensor that shuts off the ignition if the motorcycle rolls on its side. This feature is disabled when the HI-4N ignition is installed.

Daytona Beach, FL 32117 | www.cranecams.com | Phone: 866-388-5120 | Fax: 386-236-9983

6/12 9000-61002

1.Identifyswitched+12voltwireandtachwire(ifequipped)goingtothecoil.Refertoyourservicemanual,orreconnectthebat-teryanduseatestlightorvoltmeter.Theswitched+12voltwirewillbehotwhentheignitionkeyisturnedon.

2.RefertoFigure5,6,or11dependingonyourapplication.ConnecttheHI-4Nwhitewireandswitched+12voltwiretoCoil+(positive).

3.ConnecttheHI-4NpinkwiretotheCoil–terminalonthecoilforthefrontcylinder.

4.ConnecttheHI-4NbluewiretotheCoil–terminalonthecoilfortherearcylinder.

5.ConnecttheHI-4Nvioletwiretothevacuumswitch(Figure3,item18),ifused.

6.ConnecttheHI-4Nbrownwiretothetachwire,ifequippedwithatachometer.Tapeupifunused.

7.The HI-4N is grounded via the timing housing; a separategroundconnectionisnotrequired.

8.Reconnectbatterygroundcable.Verifypropergroundconnec-tionstotheframeandengine.

HI-4N INSTALLATION RefertoFigure4.TheHI-4NrequiresOEtimingrotorP/N32402-83,orCraneCamsPartNumber8-1150.Checkyourrotor(9)forcorrectpartnumber.Formodelspriorto1980,usethesupplied10-32x3/4”boltandwashertomounttherotor.

1.InstallHI-4NsysteminplaceofOEbreakerorsensorplate.RotatetheHI-4Nabout90degreestogivebetteraccesstothecableexitholeinthegearcasecover.Onsomeearlymodelsitmaybeneces-sarytoenlargethishole.InstalltheHI-4Nfirst,thenpushthecablethroughthehole.AligntheVnotchontheHI-4NsameastheOEplateyouremoved.UsetheOEstandoffstosecuretheHI-4N.Youmust use lockwashers under the standoffs for proper clearancebetweentheHI-4Nandcoverplate.Donotfullytightenthestandoffsuntilthetiminghasbeenset.

2.RoutetheHI-4Nharnessalongtheframerailstothecoil.Makesurethatharnesswillnotbechafedorburnedbyexhaustheat.Secureharnesswithtiewraps.Donotinstalltimingcover.

HI-4N HOOKUPCrimpterminalsandhardwarearesuppliedforyourconvenience.Usetheringterminalsforcoilhookup.Usemale-femalequickdis-connectsforconnectionstothetachandvacuumswitch(VOES).Tapeupunusedwires.

1. Circuit Breaker Cover Screws (2)2. Circuit Breaker Cover3. Circuit Breaker Cover Gasket4. Breaker Plate Screws (2)5. Breaker Plate Screw Lockwashers & Washers (2 each)6. Retainer (1971 to early 1972)

7. Circuit Breaker Cam Bolt8. Breaker Plate Assembly9. Breaker Cam10. Advance Assembly11. Gear Case Cover

11

10

9 8

76

5 43

2

1

Figure 1. Harley-Davidson® OE Points System

17

16

1. Cover Screws (2)2. Ignition Timer Cover3. Ignition Module4. Timer Plate Screws (2)5. Washers (2)6. Screws & Washers (2 each)7. Shield8. Sensor9. Trigger Rotor Bolt

10. Timer Plate11. Trigger Rotor12. Advance Assembly13. Gear Case Cover14. Ignition Coil15. Spark Plug Wires (2)16. Ignition Coil Terminal (FX)17. Ignition Coil Terminal (FL)

15

1413

12

11 10

9 8 76 5

43

21

Figure 2. Harley-Davidson® 1978-79 OE Electronic System

NOTE: Damage will result if the brown tach wire comes in contact with +12V.

6/12 9000-610033

1. Screws (2)2. Washers (2)3. Ignition Module4. Well Nuts (2)5. Rivets (2)6. Outer Cover7. Inner Cover Screws (2)8. Inner Cover9. Gasket10. Sensor Plate Screws & Washers (2 each)11. Sensor Plate12. Rotor Screw & Star Washer

13. Rotor14. Gear Case Cover15. Ignition Coil16. Ignition Coil Terminal

17. Spark Plug Wires (2)18. Vacuum Operated Electrical Switch (VOES)19. VOES Connector20. Sensor Connector

14

15

16 17

18

19

20

1234

567

89

10

1112

13

Figure 3. Harley-Davidson® 1980 and Later OE Electronic System

HI-4NUnit

Use SuppliedGasket

123

45

6

7

8

9

10

MINMAX

-5 0

SPKADV

RACEONLY ALLOEPOINTS

ELECSTART

1. Buttonhead Screws (2)2. Outer Cover3. Inner Cover Screws (2)4. Inner Cover

5. Gasket6. Sensor Plate Screws & Washers (2 each)7. HI-4N Unit8. Rotor Screw & Star Washer9. Rotor10. Gear Case Cover

Figure 4. HI-4N Ignition System Installation

6/12 9000-610044

VOES HOOKUP TheOEvacuumswitch(VOES)isnormallyanopencircuit.Above3-5inch-Hgvacuum,theVOESclosesandgroundsthevacuuminputontheOEmodule.Thisincreasesthetotaladvancegener-atedbytheOEignitionmodule.Vacuumadvanceimprovespartthrottledriveabilityandfueleconomy.ConnecttheVOEStotheHI-4NvioletwireasshowninFigures5,6,and11.

MODELS WITHOUT OE VACUUM SWITCH (VOES)This includes most models prior to 1985. Fuel economy anddriveabilitywillbe improved if you installaVOESandconnectittotheHI-4NvioletwireasshowninFigures5,6,and11.WerecommendyouuseH-D®VOESP/N26566-91.IftheVOESisnotused,tapeupthevioletwire.

HI-4N SETUP AND OPERATION Refer to thecoverplateon theHI-4N,and theswitch tableonpage 6. The unit has four switches that select the operatingmodes,advancerate,andrevlimit.

Thetopswitchsetstheoperatingmode.UsetheOEMwithVOESadvancecurveforstockandmodifiedengineswithOEelectronicorpointsignition.UsetheRaceOnlyadvancecurveforhighcom-pressionengines.Kickstartmodefiresthefirstcylinderforquickstarting.Electricstartmodedelaysfiringfor2revolutionsofthecrankshaftforsmootherstartsandlessstrainonthestarter.

The advance curve is adjustable over a limited range via theadvance rate switch (SPKADV).Advance curves are given in

O.E. WHITE WIRETO COIL +

GROUND

RPMX100

FRONTSPARK PLUG

REARSPARK PLUG

– +

12 VOLTBATTERY

IGNITIONSWITCH

+12V

IGNITIONCOIL

IGNITIONCOIL

TO IGNITION SWITCH

FRONT COIL

REAR COIL

HI-4N BLUE WIREHI-4

N W

HITE

WIR

E

HI-4

N P

INK

WIR

E

VOES(VACUUM SWITCH)

BROWN

ALTERNATE HOOKUP USING TWO DUAL TOWER COILS

NOTE:

If TACH or VOES are not used,tape up the corresponding wire.

HI-4N IGNITION

Figure 5. HI-4N Single Fire System Hookup with Single Plug Heads

PINK

WHI

TE

BLUE

VIOLET

MODE SWITCH MUST BE SET TO 0, 1, 2, 3, OR 8 FOR SINGLE FIRE APPLICATIONS

MODE

ADVANCE RATE

X1000RPM LIMIT

X100

8-6100

HI-4N

FRONTSPARK PLUG

REARSPARK PLUG

CRANE 8-3005SINGLE FIRE COIL

NOTE: Most motorcycle coils do not have terminals marked. Most singlefire coils use the center terminal for +12V and the outer two terminals for front and rear cylinder Coil–. For dualfire coils use either terminal for Coil+ and the other one for Coil–.

NOTE: 1996 and later models use a 2 wire connector between the VOES and the OE harness. Connect one wire from the VOES switch to frame ground and connect the other wire to the VOES input (violet wire) on the HI-4N.

6/12 9000-61005

TheRPMlimitswitches(RPMLIMIT)areadjustablefrom1,500to9,900PRM.UseasafeRPMforyourengine.DonotsetRPMlimitbelow1500.

TheHI-4timingLEDshouldlightupwhentheignitionkeyisturnedon.ThetimingLEDwillgooffwhenthecrankshaftisrotatedpastTDC.Duringcranking,theLEDwillblink.

Figures7and8.Eachsetofadvancecurves includesminimumandmaximumcurves.Theactualadvancecurvewillbebetweentheminimumandthemaximumcurvesdependingontheadvanceswitchsetting.

Ifyouhaveapassengerorareusinglowoctanegasoline,minimumadvancewillreducesparkknock.Maximumadvancewillgivehigherperformance,butmayrequiretheuseofhighoctanegasoline.

O.E. WHITE WIRETO COIL +

GROUND

RPMX100

– +

12 VOLTBATTERY

IGNITIONSWITCH

+12V

IGNITIONCOIL

IGNITIONCOIL

FRONT COILAND

SPARK PLUGS

REAR COILAND

SPARK PLUGS

BLUE

WHI

TE

BROWN

PINK

VIOLET

CRANE 8-3006OR SIMILAR

DUAL TOWERCOILS SHOWN

NOTE:

If TACH or VOES are not used,tape up the corresponding wire. VOES

(VACUUM SWITCH)

Figure 6. HI-4 Single Fire System Hookup with Dual Plug Heads

HI-4N IGNITION

MODE SWITCH MUST BE SET TO 0, 1, 2, 3, OR 8 FOR SINGLE FIRE APPLICATIONS

MODE

ADVANCE RATE

X1000RPM LIMIT

X100

8-6100

HI-4N

6/12 9000-61006

MODE SWITCH SETTINGS0 SingleFire,SingleSpark,RaceCurve,ElectricStart1 SingleFire,SingleSpark,OECurve,ElectricStart

2 SingleFire,MultiSpark,RaceCurve,ElectricStart3 SingleFire,MultiSpark,OECurve,ElectricStart4 DualFire,SingleSpark,RaceCurve,ElectricStart5 DualFire,SingleSpark,OECurve,ElectricStart6 DualFire,MultiSpark,RaceCurve,ElectricStart7 DualFire,MultiSpark,OECurve,ElectricStart8 SingleFire,SingleSpark,OECurve,KickStart9 DualFire,SingleSpark,OECurve,KickStart

TIMING MARKS TheTDCandadvance timingmarksare locatedon theflywheelandcanbeobservedviaaninspectionhole(refertoshopmanualfordetails).Refer toFigure9 for typical timingmarks.EarlyStyleincludesmost1980andearliermodels.LateStyle includesmost

Figure 7. OEM (with VOES) Advance Curves Based on TDC Initial Timing

Figure 8. Race Advance Curves Based on TDC Initial Timing

NOTE: 1996 and later models (1995 and later for export models) have a timing mark at 20° BTDC for setting the timing with the OE ignition module. Do not use this mark for setting the timing on the HI-4N. In most cases an additional mark will remain at 35° BTDC (see Figure 9). Use this mark to set the timing with a timing light as described below.

1981-95models.Iftheshopmanualisnotavailable,removesparkplugs,turnengineuntilfrontpistonisatTDConcompressionstrokeandidentifyTDCmarkontheflywheel.RefertoFigure9andfindthe diagramwith amatching TDCmark. Use the correspondingadvancemarkshowninthediagram.

INITIAL STATIC TIMING PROCEDURE Inmost cases, aligning theV notch on theHI-4N plate to thesamelocationastheOEplatewillsetthetimingcloseenoughtostarttheengine.Iftheenginewillnotstartorrunsveryrough,youcanusethefollowingstatictimingprocedure.

6/12 9000-61007

Runtheengineat2,500RPM.AdjustHI-4NpositionuntilTDCtimingmarkiscenteredintheobservationhole.Youwillnowhavetheamountofadvanceyoudialed into the timing light.Tightenthestandoffsandverifythattiminghasnotshifted.Mostdial-backtiminglightswillbecompatiblewithsinglefiresystems.

ADVANCE CURVE SETUP Afteryouhavesetthetimingasexplainedabove,settheHI-4Nadvanceswitch todesiredposition. Ifyou run93octanegaso-line,youcansettheswitchtoposition9formaximumadvanceandperformancewithoutsparkknock.Highcompressionenginesmayrequirelessadvance.YoushouldusetheRaceOnlyadvancecurveforhighcompressionengines.

RemovesparkplugsandturnengineuntilTDCmarkappearsinobser-vationhole.Groundsparkplugswithanalligatorclipsoyouwillnotshockyourself.Turnon ignition.LoosenthestandoffsholdingHI-4NandrotateunitclockwiseuntiltimingLEDgoesout.ThepointatwhichLEDgoesoffisTDC.TimingisnowsetapproximatelyatTDC.Turnoffignitionandreinstallsparkplugs.Oncetheenginehasbeenstarted,youmustsetthetimingwithatiminglight.

Theticmarksontheoutsideoftheignitionmountingslotscanbeusedfortimingreference.Thereis10°betweenthelargeticmarksand5°betweenthelargeandsmallticmarks.

IncreasetheadvancebyrotatingtheignitionclockwiseasshownbytheADVmarkingandarrowontheignitionneartheModeSelectswitch.(Figure10)

Mostkickstartapplicationworkbestwithaninitialtimingof8°.Electricstartapplicationsworkwellwith5°.

SETTING ADVANCE TIMING USING STANDARD TIMING LIGHT ThistimingprocedurerequiresthataVOESswitchbeconnectedtotheHI-4N.ForracingandearlypointsapplicationswithoutaVOESswitch,youmustgroundtheVOESinput(HI-4Nvioletwire)whilesettingthetiming.Connectatiminglighttothefrontcylin-der.SettheHI-4Nadvanceswitchtomidrange.Runtheengineat2,400to2,500RPM.AdjustHI-4Npositionuntiladvancetimingmark iscentered in theobservationhole.Tighten thestandoffsandverifythattiminghasnotshifted.

SETTING PRECISE ADVANCE TIMING FOR RACING USING DIAL BACK TIMING LIGHT Determinetheadvanceyouwantat2,500RPM.Useadialbacktiminglight.Settheamountofadvanceyouwant,say35degrees,onthedial-backtiminglight.Connectthedial-backtiminglighttothefrontcylinder.IftheVOESisused,disconnecttheVOESinput(HI-4Nvioletwire)whilesettingthetimingwiththisprocedure.SettheHI-4Nadvanceswitch toposition9 formaximumadvance.

Figure 10.

10˚ TIMING DIFFERENCE BETWEEN LARGE TIC MARKS

5˚ TIMING DIFFERENCE BETWEEN LARGE AND SMALL TIC MARKS

Early Style

Front Cylinder TDC Mark

Late Style

Front Cylinder Advance Mark

kraM ecnavdA rednilyC tnorFkraM CDT rednilyC tnorF

Front Cylinder 35° MarkFront Cylinder 20° MarkDO NOT USE

1996 and Later Models (1995 and Later Export)

Front Cylinder TDC Mark

Figure 9. Top Dead Center (TDC) and Front Cylinder Advance Marks for Various Models

6/12 9000-61008

4.Check for low voltage from a faulty or marginal chargingsystemandbattery.

5.Ifalloftheaboveconditionshavebeenchecked,contacttech-supportforassistance.

CHECKING FOR SPARK Tocranktheengineandcheckforspark,useaKDToolstestplugorH-D® toolHD-26792.These test plugs comewith analliga-torclipthatmustbeattachedtoframeorengineground.Usealengthofsparkplugwiretoconnectthetestplugtothecoil.

MISFIRE OR INTERMITTENT OPERATION Fieldexperiencehasshownthatpoppingbackthroughthecarbure-tor,misfiring,andintermittentfailure(especiallyaftertheenginegetshot)areusuallynotcausedbyelectricalproblemswithintheHI-4N.Carburetorproblems,fouledsparkplugs,coilfailure,andloosewireharnessconnectionsarethemostcommonculprits.Also,verifythatspiralcoreorsuppressiontypesparkplugwiresandresistorsparkplugsarebeingused.

TACH INOPERATIVE If the tach is inoperative after installation of theHI-4N, youmayrequirea tachadapter.TheHI-4N tachoutput is compatiblewithground sensing tachs which includes most OE and aftermarkettachs.Sometachsrequireahighvoltagetriggerpulse.Inthiscase,installCraneCamstachadapterP/N8-2050.NotethatthetachwillreadcorrectlyattherevlimitonlyifitisconnectedtothebrownwirefromtheHI-4N.DamagetotheHI-4Ncircuitrymayhaveoccurredif12voltswasappliedtothebrowntachwireatanytime.

COVER PLATE ASSEMBLY Youcanre-usetheOEhardware,andthesuppliedCraneCamsgasketfortheHI-4N.Formodelswitharivetedoutercover,usethesuppliedself-threadingscrewsinplaceoftherivets.

TROUBLESHOOTING DidtheenginerunproperlybeforeinstallationoftheHI-4N?Ifnot,removetheHI-4N,reinstalltheOEignitionoranotherknowngoodunitandthenfindandcorrecttheoriginalproblem.DidtheHI-4Nfunctioncorrectlybeforetheproblemoccurred?Iftheanswerisyes,didyouchangeanythingthatmayhaveaffectedit?TrygoingbacktothelastsetupthatworkedOKtohelpisolatetheproblem.

Iftheenginewillnotstart,orrunsroughorintermittently,usethefollowingcheckliststeps:

ENGINE WILL NOT START

1.CheckthattimingLEDlightsupand stays onwhenignitionkeyisfirstturnedon.Ifnot,checkfor+12voltsonwhitewirefromHI-4N.

2.CheckthattimingLEDblinkswhileengineiscranked.

3.IfthetimingLEDblinks,butenginewillnotstart,recheckallwireharnessconnectionsorreplacecoil(s).

O.E. WHITE WIRETO COIL +

GROUND

RPMX100

REARSPARK PLUG

FRON TSPARK PLUG

– +

12 VOLTBA TTERY

IGNITIONSWITCH

+12V

IGNITIONCOIL

VOES(VACUUM SWITCH)

VIOLET

WHI

TE

BROWN

NO TE:

If TACH or VOES are not used,tape up the corresponding wire

PINK

TAPE UP UNUSEDBLUE WIRE

CRANE 8-3006OR SIMILAR

DUAL TOWER COIL

HI-4N IGNITION

MODE SWITCH MUST BE SET TO 4, 5, 6, 7, OR 9 FOR DUAL FIRE APPLICATIONS

MODE

ADVANCE RATE

X1000RPM LIMIT

X100

8-6100

HI-4N

Figure 11. HI-4N Dual Fire System Hookup

NOTE: The battery ground on most Harley- Davidsons® is connected to the frame behind the seat. In order to provide a dedicated ground for the high starter current, another cable should be installed from the point on the frame that the battery is already grounded to the starter mounting flange. This cable should be the same diameter as the battery ground cable presently on the bike, and will help prevent damage to your electronic components.

WARNING: Never crank the engine with any spark plug wire disconnected.