HI-4N MOTORCYCLE IGNITION
Contents
1. wo O MIN ADV LOW VAC MAX ADV LOW VAC TOTAL ADVANCE CRANK DEGREES N 1000 2000 3000 4000 5000 MIN ADVAHIGH VAC MAX ADV HIGH VAC 6000 7000 8000 9000 ENGINE RPM Figure 8 Race Advance Curves Based on TDC Initial Timing A Oo wo oO y ax Oo TOTAL ADVANCE CRANK DEGREES N is va ee Ct en Cnet eC O MIN ADVANCE E MAX ADVANCE a HIGH VACUUM VOES GROUNDED 1000 2000 3000 4000 5000 6000 7000 8000 9000 ENGINE RPM 6 12 6 9000 6100 Figure 9 Top Dead Center TDC and Front Cylinder Advance Marks for Various Models yy NS Front Cylinder TDC Mark Front Cylinder Advance Mark Late Style i Front Cylinder TDC Mark Front Cylinder Advance Mark 1996 and Later Models 1995 and Later Export Front Cylinder TDC Mark Remove spark plugs and turn engine until TDC mark appears in obser vation hole Ground spark plugs with an alligator clip so you will not shock yourself Tum on ignition Loosen the standoffs holding HI 4N and rotate unit clockwise until timing LED goes out The point at which LED goes off is TDC Timing is now set approximately at TDC Tum off ignition and reinstall spark plugs Once the engine has been started you must set the timing with a timing light The tic marks on the outside of the ignition mounting slots can be used for timing reference Ther2. Adjust HI 4N position until TDC timing mark is centered in the observation hole You will now have the amount of advance you dialed into the timing light Tighten the standoffs and verify that timing has not shifted Most dial back timing lights will be compatible with single fire systems ADVANCE CURVE SETUP After you have set the timing as explained above set the HI 4N advance switch to desired position If you run 93 octane gaso line you can set the switch to position 9 for maximum advance and performance without spark knock High compression engines may require less advance You should use the Race Only advance curve for high compression engines Figure 10 10 TIMING DIFFERENCE BETWEEN LARGE TIC MARKS 5 TIMING DIFFERENCE BETWEEN LARGE AND 6 12 9000 6100 Figure 11 HI 4N Dual Fire System Hookup IGNITION SWITCH O E WHITE WIRE TO COIL i 12 VOLT BATTERY MODE SWITCH MUST BE SET TO 4 5 6 7 OR 9 FOR DUAL FIRE APPLICATIONS NOTE CRANE 8 3006 OR SIMILAR DUAL TOWER COIL FRONT SPARK PLUG IGNITION COIL REAR SPARK PLUG VIOLET TAPE UP UNUSED BLUE WIRE VOES VACUUM SWITCH If TACH or VOES are not used tape up the corresponding wire COVER PLATE ASSEMBLY You can re use the OE hardware and the supplied Crane Cams gasket for the HI 4N For models with a riveted outer cover use the supplied self threading screws in place of the rivets TROUBLESHOOTING Did the engine
3. To crank the engine and check for spark use a KD Tools test plug or H D tool HD 26792 These test plugs come with an alliga tor clip that must be attached to frame or engine ground Use a length of spark plug wire to connect the test plug to the coil WARNING Never crank the engine with any spark plug wire disconnected MISFIRE OR INTERMITTENT OPERATION Field experience has shown that popping back through the carbure tor misfiring and intermittent failure especially after the engine gets hot are usually not caused by electrical problems within the HI 4N Carburetor problems fouled spark plugs coil failure and loose wire harness connections are the most common culprits Also verify that spiral core or suppression type spark plug wires and resistor spark plugs are being used TACH INOPERATIVE If the tach is inoperative after installation of the HI 4N you may require a tach adapter The HI 4N tach output is compatible with ground sensing tachs which includes most OE and aftermarket tachs Some tachs require a high voltage trigger pulse In this case install Crane Cams tach adapter P N 8 2050 Note that the tach will read correctly at the rev limit only if it is connected to the brown wire from the HI 4N Damage to the HI 4N circuitry may have occurred if 12 volts was applied to the brown tach wire at any time 6 12 9000 6100
4. 12 volt wire will be hot when the ignition key is turned on 2 Refer to Figure 5 6 or 11 depending on your application Connect the HI 4N white wire and switched 12 volt wire to Coil positive 3 Connect the HI 4N pink wire to the Coil terminal on the coil for the front cylinder 4 Connect the HI 4N blue wire to the Coil terminal on the coil for the rear cylinder 5 Connect the HI 4N violet wire to the vacuum switch Figure 3 item 18 if used 6 Connect the HI 4N brown wire to the tach wire if equipped with a tachometer Tape up if unused 7 The HI 4N is grounded via the timing housing a separate ground connection is not required 8 Reconnect battery ground cable Verify proper ground connec tions to the frame and engine 6 12 9000 6100 OMAN OAK ON es ks N 6 12 Figure 3 Harley Davidson 1980 and Later OE Electronic System Screws 2 13 Rotor Washers 2 14 Gear Case Ignition Module Cover Well Nuts 2 15 Ignition Coil Rivets 2 16 Ignition Coil Outer Cover Inner Cover Screws 2 Inner Cover Gasket Sensor Plate Screws Terminal amp Washers 2 each Sensor Plate Rotor Screw amp Star Washer 17 Spark Plug Wires 2 18 Vacuum Operated Electrical Switch VOES 19 VOES Connector Sensor Connector 9 gt Figure 4 HI 4N Ignition System Installation 1 Buttonhead Screws 2 Gasket 2 Outer Cover Sensor Pl
5. 2 ohms primary resistance Coils with 4 ohms or higher may be used but may not produce optimum output We recommend the following coils for single and dual plug applications HI 4N Ignition With Single Plug Heads Use Crane Cams P N 8 3005 coil which will fit in the stock mounting location on most H D motorcycles You can also use two dual spark tower coils and ground one of the towers on each coil to the engine case or frame You will have to fabricate a bracket to mount the second coil HI 4N Ignition With Dual Plug Heads Use two Crane 8 3006 coils You will have to fabricate a bracket to mount the second coil Crane FireWire spiral core wires are recommended for maximum performance Do not use solid copper spark plug cables they may cause interference with your ignition system and accessories REMOVAL OF POINTS IGNITION EARLY MODELS PRIOR TO 1978 1 Turn ignition switch off and disconnect battery ground cable Disconnect wire going from breaker points to Coil negative terminal 2 Refer to Figure 1 Remove ignition cover plate gasket and hardware items 1 3 Save these items for later re use 3 Note location of breaker plate There is a V notch in the breaker plate used for alignment When you install the HI 4N align the V notch in the same location This should set the timing close enough to start the engine Remove and save the two standoffs and washers items 4 5 Remove the breaker plate assembly wiring cam
6. GROUND MODE SWITCH MUST BE SET TO 0 1 2 3 OR 8 FOR SINGLE FIRE APPLICATIONS O HI 4N MODE ADVANCE RATE x1000 4 RPM LIMIT x1004 RANE ams 8 6100 HI 4N IGNITION NOTE If TACH or VOES are not used tape up the corresponding wire Figures 7 and 8 Each set of advance curves includes minimum and maximum curves The actual advance curve will be between the minimum and the maximum curves depending on the advance switch setting If you have a passenger or are using low octane gasoline minimum advance will reduce spark knock Maximum advance will give higher performance but may require the use of high octane gasoline REAR COIL AND SPARK PLUGS VIOLET VOES VACUUM SWITCH The RPM limit switches RPM LIMIT are adjustable from 1 500 to 9 900 PRM Use a safe RPM for your engine Do not set RPM limit below 1500 The HI 4 timing LED should light up when the ignition key is turned on The timing LED will go off when the crankshaft is rotated past TDC During cranking the LED will blink 6 12 5 9000 6100 MODE SWITCH SETTINGS Single Fire Single Spark Race Curve Electric Start Single Fire Single Spark OE Curve Electric Start Single Fire Multi Spark Race Curve Electric Start Single Fire Multi Spark OE Curve Electric Start Dual Fire Single Spark Race Curve Electric Start Dual Fire Single Spark OE Curve Electric Start Dual Fire Multi Spark Race Curve Ele
7. run properly before installation of the HI 4N If not remove the HI 4N reinstall the OE ignition or another known good unit and then find and correct the original problem Did the HI 4N function correctly before the problem occurred If the answer is yes did you change anything that may have affected it Try going back to the last setup that worked OK to help isolate the problem If the engine will not start or runs rough or intermittently use the following checklist steps ENGINE WILL NOT START 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 1 Check that timing LED lights up and stays on when ignition key is first turned on If not check for 12 volts on white wire from HI 4N 2 Check that timing LED blinks while engine is cranked 3 If the timing LED blinks but engine will not start recheck all wire harness connections or replace coil s 4 Check for low voltage from a faulty or marginal charging system and battery 5 If all of the above conditions have been checked contact tech support for assistance CHECKING FOR SPARK
8. RANE ams iG NIIT IiI ORN Installation Instructions for HI 4N MOTORCYCLE IGNITION For more information see www cranecams com CAUTION READ INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION INTRODUCTION The HI 4N ignition system is intended for use with Harley David son motorcycles The HI 4N replaces the original equipment OE electronic ignition system on 1978 and later models as well as the points and mechanical advance on early models Will not work in 2000 2003 Sportster 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 The HI 4N features state of the art technology that allows adjustable advance and rev limit A timing LED indicates static timing top dead center and gives diagnostic information Two starting modes are provided electric start and kick start A tach output gives accurate tach readings even at the rev limit ADDITIONAL REQUIRED PARTS FX series Big Twin and XL series Sportster models prior to 1984 FL series Big Twin models prior to 1985 and all models with OE points will require OE timing rotor P N 32402 83 This part is not included with the HI 4N installation kit and can be purchased separately Crane Cams Part Number 8 1150 COIL AND SPARK PLUG CABLE CONSIDERATIONS We recommend replacing the OE coil Coils used with the HI 4N must have at least
9. and advance assembly items 6 10 REMOVAL OF OE ELECTRONIC IGNITION SYSTEM 1978 AND 1979 MODELS 1 Turn ignition switch off and disconnect battery ground cable 2 Refer to Figure 2 Disconnect wires going from ignition module item 3 to coil 14 3 Remove ignition cover plate and hardware items 1 and 2 Save these items for later re use Remove ignition module 3 4 Note location of timer plate 10 There is a V notch in the timer plate used for alignment When you install the HI 4N align the V notch in the same location This should set the timing close enough to start the engine Remove and save the two standoffs and washers items 4 5 Remove the sensor shield timer plate trigger rotor and advance assembly items 6 12 REMOVAL OF OE ELECTRONIC IGNITION SYSTEM 1980 AND LATER MODELS 1 Turn ignition switch off and disconnect battery ground cable 2 Refer to Figure 3 Remove OE ignition module and wire harness items 1 4 You will disconnect two wires at the coil wire going to the VOES Vacuum Operated Electrical Switch ground wire at the module and the 3 pin plug 20 that connects to the sensor plate Refer to shop manual for locations 3 Remove ignition cover plates and gasket items 5 9 This will require drilling out two rivets The rivets will later be replaced with two supplied self threading screws 4 In order to remove the sensor plate cable the cable plug 20 must be removed first Use
10. ate Screws amp 3 Inner Cover Screws 2 Washers 2 each 4 Inner Cover 7 HI 4N Unit 8 Rotor Screw amp Star Washer 9 Rotor 10 Gear Case Cover HI 4N ynit Use Supplied wee Gasket 9000 6100 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 VOES HOOKUP The OE vacuum switch VOES is normally an open circuit Above 3 5 inch Hg vacuum the VOES closes and grounds the vacuum input on the OE module This increases the total advance gener ated by the OE ignition module Vacuum advance improves part throttle driveability and fuel economy Connect the VOES to the HI 4N violet wire as shown in Figures 5 6 and 11 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 MODELS WITHOUT OE VACUUM SWITCH VOES This includes most models prior to 1985 Fuel economy and driveability will be improved if you install a VOES and connect it to the HI 4N violet wire as shown in Figures 5 6 and 11 We recommend you use H D VOES P N 26566 91 If the VOES is not used tape up the violet wire HI 4N SETUP AND OPERATION Refer to the cover plate on the HI 4N and the switch tab
11. ctric Start Dual Fire Multi Spark OE Curve Electric Start Single Fire Single Spark OE Curve Kick Start Dual Fire Single Spark OE Curve Kick Start TIMING MARKS The TDC and advance timing marks are located on the flywheel and can be observed via an inspection hole refer to shop manual for details Refer to Figure 9 for typical timing marks Early Style includes most 1980 and earlier models Late Style includes most OMAN DOA FR WNY O 1981 95 models If the shop manual is not available remove spark plugs turn engine until front piston is at TDC on compression stroke and identify TDC mark on the flywheel Refer to Figure 9 and find the diagram with a matching TDC mark Use the corresponding advance mark shown in the diagram 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 INITIAL STATIC TIMING PROCEDURE In most cases aligning the V notch on the HI 4N plate to the same location as the OE plate will set the timing close enough to start the engine If the engine will not start or runs very rough you can use the following static timing procedure Figure 7 OEM with VOES Advance Curves Based on TDC Initial Timing A O
12. e is 10 between the large tic marks and 5 between the large and small tic marks Increase the advance by rotating the ignition clockwise as shown by the ADV marking and arrow on the ignition near the Mode Select switch Figure 10 Most kick start application work best with an initial timing of 8 Electric start applications work well with 5 SETTING ADVANCE TIMING USING STANDARD TIMING LIGHT This timing procedure requires that a VOES switch be connected to the HI 4N For racing and early points applications without a VOES switch you must ground the VOES input HI 4N violet wire while setting the timing Connect a timing light to the front cylin der Set the HI 4N advance switch to midrange Run the engine at 2 400 to 2 500 RPM Adjust HI 4N position until advance timing mark is centered in the observation hole Tighten the standoffs and verify that timing has not shifted SETTING PRECISE ADVANCE TIMING FOR RACING USING DIAL BACK TIMING LIGHT Determine the advance you want at 2 500 RPM Use a dialback timing light Set the amount of advance you want say 35 degrees on the dial back timing light Connect the dial back timing light to the front cylinder If the VOES is used disconnect the VOES input HI 4N violet wire while setting the timing with this procedure Set the HI 4N advance switch to position 9 for maximum advance Front Cylinder 20 Mark DO NOT USE Front Cylinder 35 Mark Run the engine at 2 500 RPM
13. le on page 6 The unit has four switches that select the operating modes advance rate and rev limit The top switch sets the operating mode Use the OEM with VOES advance curve for stock and modified engines with OE electronic or points ignition Use the Race Only advance curve for high com pression engines Kick start mode fires the first cylinder for quick starting Electric start mode delays firing for 2 revolutions of the crankshaft for smoother starts and less strain on the starter The advance curve is adjustable over a limited range via the advance rate switch SPK ADV Advance curves are given in Figure 5 HI 4N Single Fire System Hookup with Single Plug Heads IGNITION SWITCH O E WHITE WIRE TO COIL 12 VOLT BATTERY MODE SWITCH MUST BE SET TO 0 1 2 3 OR 8 FOR SINGLE FIRE APPLICATIONS KES ET ADVANCE RATE g o i HI 4N IGNITION NOTE If TACH or VOES are not used ALTERNATE HOOKUP USING TWO DUAL TOWER COILS TO IGNITION SWITCH FRONT SPARK PLUG IGNITION COIL REAR IGNITION SPARK PLUG colL HI 4N_WHITE WIRE HI 4N_PINK WIRE CRANE 8 3005 SINGLE FIRE COIL VIOLET VACUUM SWITCH tape up the corresponding wire 6 12 9000 6100 Figure 6 HI 4 Single Fire System Hookup with Dual Plug Heads IGNITION SWITCH O E WHITE WIRE TO COIL CRANE 8 3006 OR SIMILAR DUAL TOWER FRONT COIL AND SPARK PLUGS COILS SHOWN 12 VOLT BATTERY
14. needle nose pliers to pull the termi nals out of the plug Then pull the cable through the exit hole at the bottom of the timing cover 5 Note location of sensor plate 11 There is a V notch in the sensor plate used for alignment When you install the HI 4N you should align the V notch in the same location This should set the timing close enough to start the engine Remove and save the two stand offs and washers 10 Remove the sensor plate item 11 CEAN Daytona Beach FL 32117 www cranecams com Phone 866 388 5120 Fax 386 236 9983 6 12 9000 6100 Figure 1 Harley Davidson OE Points System Circuit Breaker Cover Screws 2 Circuit Breaker Cover Circuit Breaker Cover Gasket Breaker Plate Screws 2 Breaker Plate Screw Lockwashers amp Washers 2 each Retainer 1971 to early 1972 7 Circuit Breaker Cam y 8 Breaker Plate Assembly 9 Breaker Cam 10 Advance Assembly 11 Gear Case Cover Figure 2 Harley Davidson 1978 79 OE Electronic System Cover Screws 2 Ignition Timer Cover 11 Trigger Rotor Ignition Module 12 Advance Assembly Timer Plate Screws 2 13 Gear Case Cover Washers 2 14 Ignition Coil Screws amp Washers 2 each 15 Spark Plug Wires 2 Shield 16 Ignition Coil Terminal FX Sensor Ignition Coil Terminal FL Trigger Rotor Bolt OMNADAAWHD A HI 4N INSTALLATION Refer to Figure 4 The HI 4N requires OE timing rotor P N 32402 83 o
15. r Crane Cams Part Number 8 1150 Check your rotor 9 for correct part number For models prior to 1980 use the supplied 10 32 x 3 4 bolt and washer to mount the rotor 1 Install HI 4N system in place of OE breaker or sensor plate Rotate the HI 4N about 90 degrees to give better access to the cable exit hole in the gear case cover On some early models it may be neces sary to enlarge this hole Install the HI 4N first then push the cable through the hole Align the V notch on the HI 4N same as the OE plate you removed Use the OE standoffs to secure the HI 4N You must use lock washers under the standoffs for proper clearance between the HI 4N and cover plate Do not fully tighten the standoffs until the timing has been set 2 Route the HI 4N hamess along the frame rails to the coil Make sure that harness will not be chafed or burned by exhaust heat Secure harness with tie wraps Do not install timing cover HI 4N HOOKUP Crimp terminals and hardware are supplied for your convenience Use the ring terminals for coil hookup Use male female quick dis connects for connections to the tach and vacuum switch VOES Tape up unused wires Timer Plate a A ZH k 16 4 NOTE Damage will result if the brown tach wire comes in contact with 12V 1 Identify switched 12 volt wire and tach wire if equipped going to the coil Refer to your service manual or reconnect the bat tery and use a test light or voltmeter The switched
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