Model 1005S EX Instructions
Contents
1. REPLACE COIL DOES ENGINE MISFIRE IS PROBLEM FIXED UNDER LOAD NO NO YES DONE CHECK FOR MINIMUM 13V AT COIL WITH ENGINE RUNNING AT 2000 RPM IS VOLTAGE OK REPLACE TWIN TEC MODULE YES NO INSTALL POWER RELAY KIT CALL TECH SUPPORT FOR DETAILS REPLACE SPARK PLUGS SPARK PLUG WIRES AND COIL IS PROBLEM FIXED YES NO DONE REPLACE TWIN TEC MODULE DOES ENGINE MISFIRE AT PART THROTTLE OR WHILE COLD NO YES CHECK FOR INCORRECT CARB JETTING OR INTAKE LEAK IS PROBLEM FIXED YES NO DONE REPLACE TWIN TEC MODULE TROUBLESHOOTING TIP If you are installing an internal nose cone ignition for the first time and the engine will not start the most likely problem is improper static timing Make sure that the front piston is at TDC on the compression stroke and not on the exhaust stroke Also check the bank angle sensor as described above Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 386 304 0700 www daytona twintec com Model 1005S EX 5 2015 Page 82. Operating data PC Link Evo software will not allow you to exceed the values shown for the maximum advance curves in Figure 5 when programming custom advance curves for Model 1005S EX units The latest versions of our software are always available for download on our website The software is free and will work in demo mode without a Twin Tec module attached Refer to the software documentation for details The brown tachometer wire is used for the PC link The PC link can access the Twin Tec module when the ignition is turned on and the engine has not yet been started Once the engine is started the brown wire resumes its normal function of driving the tachometer Note that no damage occurs if the engine is inadvertently started while the PC link is still attached The optional USB interface cable connects to the brown tachometer wire as shown in Figures 4 and 5 The cable also has a ground clip that must be connected to frame or engine ground The other end of the cable connects to the USB port on a laptop PC Model 1005S EX 5 2015 Page 6 Figure 5 Model 1005S EX Advance Curves ADVANCE DEG MAX ADVANCE AT WIDE OPEN THROTTLE MIN ADVANCE AT WIDE OPEN THROTTLE O MAX ADVANCE WITH VOES GROUNDED O MIN ADVANCE WITH VOES GROUNDED 0 1000 2000 3000 4000 5000 6000 ENGINE RPM Figure 6 Front Cylinder Timing Marks TROUBLESHOOTING FLOWCHART Follow the tro
3. SS00L J PON uonub Insert the remaining two terminals blue and brown wires into the supplied connector shell and install the supplied secondary lock Plug the 6 pin connector back into the mating plug on the OE harness Plug the 2 pin connector into 386 304 0700 www daytona twintec com 10 the mating plug on the supplied extension harness Route the extension harness as required up to the coil for single fire hookup or to some other convenient location Make sure that the harness is clear of hot exhaust areas and cannot chafe against sharp edges Secure the harness with nylon cable ties For dual fire hookup the blue wire is not used and should be taped up Install the supplied Weather Pack connector set on the brown tachometer wire as shown If a tachometer is not used seal the end of the mating plug with silicone RTV and use it as a protective cover Use a proper Weather Pack crimping tool or solder the terminals Pioneer Standard www packard pios com sells Packard crimping tool P N 12014254 Snap on sells a low cost tool P N PWC30 Single Fire Tach Hookup If your motorcycle had a tach before installation of the Twin Tec module the tach was connected to the pink coil wire When you connect the tach direct to the Twin Tec module as shown in Figure 4 for a single fire application you must make sure that it is not still connected to the pink coil wire Trace the wire going all the way back to the tach to avoid
4. r Twin Tec Installation Instructions fo Ignition Model 1005S EX CAUTION CAREFULLY READ INSTRUCTIONS BEFORE PROCEEDING OVERVIEW Twin Tec ignition Model 1005 EX is 50 states street legal ARB E O No D 641 1 for use with the following Harley Davidson motorcycle models e All 1998 2003 XLH 883cc and 1200cc Sportster except 1200S The Model 1005S EX replaces the original equipment OE electronic ignition system The unit mounts in the gear case cover and plugs into the OE wiring harness The Model 1005S EX offers adjustable advance adjustable RPM limit settings in 100 RPM increments and switch selectable single or dual fire modes Single fire mode improves starting reduces the occurrence of backfiring at low RPM and improves power at high RPM A red status LED flashes when the engine reaches top dead center TDC and allows easy static timing The status LED also provides diagnostic information A green VOES LED illuminates when the VOES vacuum switch input is active A special feature allows use of the tachometer wire for a PC link to a laptop computer when the engine is not running Individual units can be programmed with a custom advance curve The use of the tachometer wire for the PC link eliminates the need to remove the outer cover plate All Model 1005S EX units log engine operating data that may be downloaded and viewed with our Operating Statistics software Model 1005S EX units also include a bui
5. an inadvertent coil connection CAUTION Single fire only Failure to isolate the tach wire from the coil will cause damage to the Twin Tec module that is not covered under warranty 12 13 Reconnect the battery ground cable Complete the setup and timing procedures given on pages 3 7 Reinstall the cover plate using two supplied 10 24 x 1 4 socket head screws and lock washers in place of the original rivets You will have to tap the rivet holes on the inner plate do this with the plate removed from the bike to avoid damaging the ignition You can use the supplied 10 24 x 3 8 self threading screw as a tap NOTE The unit is grounded by means of the gear case housing The mounting surface must not be anodized or painted Page 2 Model 1005S EX 5 2015 BANK ANGLE SENSOR All 1998 and later Sportster models come with a bank angle sensor The bank angle sensor functions like a switch that normally grounds the green white wire from the ignition module If the motorcycle tips over the switch opens the ignition module is disabled and the engine stops running If the bank angle sensor is defective or electrical connections are broken the engine will not start or run NOTE If the engine will not start the bank angle sensor has probably failed Ground the green white wire from the module If the engine now starts replace the failed bank angle sensor OPERATING MODES A single 10 position rotary switch is used t
6. around the end of the protective wire harness sleeve and the terminals This will compress the sleeve protect the terminals and allow you to easily feed the harness down through the exit hole The tape will also keep the sleeve end from fraying Rotate the unit slightly counterclockwise of the final orientation shown in Figure 2 and then place it into position Be careful to avoid damage to the black plastic Hall effect sensors on the bottom of the unit Route the wiring harness and install the mounting standoffs as shown in Figure 2 Do not fully tighten the standoffs or install the outer cover plate until after the static timing procedure Refer to the appropriate wiring diagram Use the dual fire hookup shown in Figure 3 if you have an OE coil or other coil with two primary terminals Use the single fire hookup in Figure 4 if you are installing an aftermarket coil with three primary terminals Four of the terminals on the Model 1005S EX wire harness go into the 6 pin connector shell you disassembled in step 2 Pin numbers are Model 1005S EX 5 2015 engraved on the back of the shell The wire colors should match up with the mating connector on the OE harness Insert the supplied white plastic seal into the empty position at pin 6 Reinstall the secondary lock Figure 1 OE Module and Deutsch Connector 8 Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 3 f 2 53 7 2
7. L NOTE IF THE ENGINE WILL 2 PIN CONNECTOR SHELL AND A RODA GHE MATING EXTENSION CABLE SUPPLIED WITH MODEL 1005S FAILED GROUND THE GREEN WHITE WIRE FROMTHE pN coLoR MODULE IF THE ENGINE NOW 1 BLUE QF TIONAL CABLE CONNECTED TO STARTS REPLACE THE FAILED 2 BROWN BANK ANGLE SENSOR 3 Ground the spark plug cables to avoid a shock the unit clockwise until the LED goes out Note that hazard You can use small jumper wires with the LED goes out at TDC Agaton Gips lon this pase 5 Tighten the standoffs to secure the unit Turn off 4 Turnon the ignition switch The red LED is used as the ignition switch and reinstall the spark plugs a timing indicator Note that the LED does not immediately illuminate when power is first turned on Rotate the ignition unit back and forth until the red LED illuminates Then slowly rotate Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 Model 1005S EX 386 304 0700 www daytona twintec com 5 2015 Page 5 PRECISE TIMING PROCEDURE 1 Use a standard timing light Note that most dial back type timing lights will not work correctly with dual fire applications If you have a dial back timing light set the dial back to zero Do not enable multi spark while setting timing 2 The precise timing procedure is based on using the 20 BTDC timing mark and maximum advance curve with VOES grounded that reaches 20 BTDC between 1 000 1 500 RPM refer
8. flywheel and may stroke Remove spark plugs and rotate crankshaft be viewed by unscrewing the inspection hole plug If you place your thumb over the spark plug hole Most engines will have both TDC and advance you will feel pressure as the piston comes up on timing marks for the front cylinder as shown in the compression stroke Continue rotating the Figure 6 If you are not sure refer to your shop crankshaft until the TDC mark is precisely centered manual You can also identify the TDC mark by in the inspection hole removing the spark plugs and rotating the crankshaft turn rear wheel in high gear until the front piston comes up on TDC Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 Model 1005S EX 386 304 0700 www daytona twintec com 5 2015 Page 4 Figure 4 Single Fire Wiring Diagram ENGINE STOP RUN SWITCH SINGLE FIRE COIL WHITE BLACK VOES VACUUM SWITCH TO FRONT SPARK PLUG WHITE BLACK TO REAR SPARK BLUE O PLUG PURPLE WHITE 6 PIN CONNECTOR SHELL REMOVED FROM HARNESS ON OE BANK HODULE f WIRE COLORS 1 PIN 1998 2001 2002 amp LATER MODE ADVANCE RPM LIMIT SELECT SLOPE Tx1000 X100 1 WHITE BLK WHITE BLK O PURPLE WHT PURPLE WHT A NOT USED NOT USED GREEN GRAY PINK GREEN GRAY GRAY WIRE GREEN GRAY TO STOP RUN PINK Kp suns O NOT USED NOT USED SWITCH voes O PATEE OPTIONAL TACH L WEATHER PACK CONNECTORS O FEMALE TERMINAL MALE TERMINA
9. ger pulse In this case you will require a commercially available tachometer adapter CAUTION Do not use solid copper spark plug cables or non resistor type spark plugs The unit may misfire Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 386 304 0700 www daytona twintec com VOES CONSIDERATIONS The vacuum switch VOES provides the vacuum advance required by all street driven engines Additional advance under low manifold pressure conditions improves idle stability and fuel economy All 1998 and later Sportster models are equipped with a OE VOES Without vacuum advance at idle and part throttle thermodynamic efficiency is reduced and engine temperatures increase significantly The VOES is normally open At low manifold pressure or manifold vacuum greater than about 5 inch Hg the VOES grounds the purple white wire and causes the Twin Tec module to generate additional timing advance The green VOES LED illuminates whenever the VOES input is active timing advanced PC LINK CABLE AND SOFTWARE The new Twin Tec USB Interface P N 18014 provides PC connectivity for all of our engine controls ignition and fuel injection systems and eliminates the requirement for multiple cables or a separate USB adapter Two Windows based programs are available for use with the Model 1005S EX PC Link Evo for programming custom advance curves and other engine parameters and Operating Statistics for viewing engine
10. ld in temperature sensor and logging of temperature data INCLUDED PARTS The unit includes a parts bag with an extension harness and crimp terminals that you can use to connect an optional single fire coil and a Packard Weather Pack connector set intended for installation on the tachometer wire to provide an access point for the PC link The Model 1005S EX must be operated with the original equipment H D timing rotor P N 32402 83 Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 386 304 0700 www daytona twintec com Page 1 INSTALLATION 1 Turn off the ignition switch and disconnect the battery ground cable before proceeding Refer to Figure 1 Disconnect the OE ignition module The plug is attached to the frame tube underneath the engine You will have to disassemble the 6 pin Deutsch connector on the module side Use needle nose pliers to pull out the secondary lock inside the connector shell Use a small screwdriver to depress the plastic terminal latches while gently pulling out each wire If you are not familiar with Deutsch connectors you can find more detailed information in the H D service manual Save the connector shell and secondary lock Remove the gear case cover plate and mounting hardware You may have to drill out two rivets that hold the cover Remove the OE module and carefully pull the harness up through the exit hole Install the Model 1005S EX unit Wrap electrical tape
11. lways requires some trial and error experimentation but maximum power is usually obtained by using the highest advance setting possible without audible spark knock Some recommended starting points are given below For engines run on normal pump gas 87 89 octane use advance slope setting 5 For engines run on 92 or higher octane gas use advance slope setting 7 If you experience spark knock use a lower advance slope setting Note that the wide open throttle WOT curves are active unless the VOES input is grounded During idle and cruise the VOES input is grounded green VOES LED illuminated and the low manifold pressure MAP curves are active TUNING TIP Excessively lean air fuel ratio AFR increases the tendency for spark knock Test the motorcycle on a dyno with an exhaust gas sniffer to check AFR and make sure the carburetor is jetted to factory specifications RPM LIMITER SETTING You can set the RPM limit from 3 000 to 9 900 RPM in 100 RPM increments by means of two rotary switches The RPM limit is X100 switch setting i e 57 5 700 RPM Inadvertent settings below 3 000 RPM are ignored and result in a 3 000 RPM limit The Model 1005S EX uses a newly developed RPM limiting algorithm that has been highly optimized for odd firing V twin engines When the engine is held against the RPM limit cylinder firing is always paired This eliminates a torque couple and results in very smooth operation compared to rand
12. o select the operating mode Switch settings are as follows 0 Dual fire multi spark disabled 1 Dual fire multi spark enabled 2 Single fire multi spark disabled 3 Single fire multi spark enabled 4 7 Same as 0 3 8 9 Reserved factory settings The engine will not run if the mode switch setting does not match the wiring hookup i e you cannot select single fire mode with a dual fire coil hookup Advance curve families are shown in Figure 5 We recommend that you enable multi spark When multi spark is enabled a continuous series of sparks is fired from the advanced timing point until TDC Most air cooled engines require relatively cold spark plugs to prevent detonation under high load Multi spark reduces the consequent tendency for plug fouling at idle Switch settings 8 9 are reserved for factory programming and test The unit will not operate with these settings RECOMMENDED TIMING SETTINGS Advance curve families are shown in Figure 5 Each family has minimum and maximum curves The advance slope switch allows you to run an advance curve in between these minimum and maximum Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 386 304 0700 www daytona twintec com curves Advance slope switch setting zero corresponds to the minimum advance curve Switch setting 9 corresponds to the maximum advance curve Higher switch settings result in a more aggressive curve Tuning a particular engine setup a
13. om or sequence type RPM limiters Set a safe RPM limit that is appropriate for your engine Most Sportster engines with OE valvetrain components should not be run over 5 700 RPM Model 1005S EX 5 2015 Page 3 Figure 3 Dual Fire Wiring Diagram ENGINE STOP RUN SWITCH bo WHITE BLACK DUAL FIRE COIL VOES AN TO FRONT VACUUM SWITCH Va SPK ED WHITE BLACK TO REAR SPARK PLUG PURPLE WHITE 6 PIN CONNECTOR SHELL REMOVED FROM HARNESS ON OE MODULE WIRE COLORS 7 MODE ADVANCE p RPM LIMIT HEC CLE are a SELECT SLOPE Ix1000 X100 Ce WHITE BLK S 23 U3 23 NOT USED NOT USED GREEN GRAY PINK PINK GREEN GRAY NOT USED NOT USED status O s vos O TwinTec Model 1005S EX ANGLE SENSOR GREEN GRAY GRAY WIRE TO STOP RUN SWITCH BLUE WIRE USED FOR SINGLE FIRE OPTIONAL CABLE CONNECTED TO ONLY TAPE UP BROWN TACH WIRE DURING PC LINK TO PC i h SERIAL NOTE IF THE ENGINE WILL BROWN NOT START THE BANK ANGLE 2 FIN CONNECTOR SHELL AND FEMALE TERMINAL MALE TERMINAL SENSOR HAS PROBABLY SUPPLIED WITH MODEL 1005S WEATHER PACK CONNECTORS FAILED GROUND THE GREEN WHITE WIRE FROM THE PIN COLOR MODULE IF THE ENGINE NOW STARTS REPLACE THE FAILED BANK ANGLE SENSOR PORT STATIC TIMING PROCEDURE 2 For static timing you must rotate the crankshaft so E that the front piston is at TDC on the compression 1 Timing marks are located on the
14. to Figure 5 To use this procedure you must have a properly functioning VOES switch connected 3 Set mode switch to 0 for dual fire or 2 for single fire Set advance slope switch to 9 Connect the timing light pickup to the front cylinder spark plug cable Loosen standoffs securing the ignition unit Run the engine at a steady speed around 1 200 RPM Verify that the green VOES LED is illuminated Rotate the ignition to center the 20 BTDC timing mark in the inspection hole Tighten standoffs and verify that the timing has not changed When done change mode and advance slope switches back to desired values GENERAL RECOMMENDATIONS Coil primary resistance must not be less than 3 ohms Most OE style dual fire and aftermarket single fire coils meet this requirement Coils for the new Twin Cam 88 engine have low primary resistance and are not compatible Due to the short lengths involved on motorcycle applications energy losses in spark plug wires are insignificant OE carbon core suppression cables will deteriorate after several years For a more durable replacement we suggest spiral core spark plug cables The Twin Tec module is compatible with all modern ground sensing type tachometers including H D OE and Autometer aftermarket units The red status LED is internally connected to the tachometer output If the red status LED blinks the tachometer output should be functional Some early tachometers require a high voltage trig
15. ubleshooting flowchart shown on the next page Experience has shown that most units returned for warranty are OK and another problem such as a defective coil is later identified 35 BTDC Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 Model 1005S EX 386 304 0700 www daytona twintec com Page 7 NOT a 7000 5 2015 Troubleshooting Flowchart TURN IGNITION ON SET ENGINE RED STATUS LED FLASH CHECK FOR 12V POWER AT MODULE WHITE WIRE WITH BLACK STRIPE AT CONNECTOR IS 12V POWER OK YES REPLACE TWIN TEC MODULE REPAIR WIRING PROBLEM REFER TO MOTORCYCLE SERVICE MANUAL GROUND GREEN WHITE WIRE FROM MODULE BANK ANGLE SENSOR INPUT DOES ENGINE START YES NO REPAIR SENSOR CHECK FOR LOW BATTERY NO FUEL OR FOULED SPARK PLUGS ANY OBVIOUS FAULT FOUND YES NO CORRECT FAULT SINGLE FIRE ONLY INSTALL POWER RELAY KIT CALL TECH SUPPORT FOR DETAILS IS PROBLEM FIXED YES NO DONE REPLACE COIL IS PROBLEM FIXED YES NO DONE DID THE ENGINE RUN PROPERLY BEFORE INSTALLATION OF THE TWIN TEC MODULE SWITCH TO RUN CRANK ENGINE DOES FOR MISC PROBLEMS REPLACE TWIN Eee adil CALL TECH SUPPPORT STARTING POINT REPAIR UNDERLYING PROBLEM BEFORE INSTALLING TWIN TEC MODULE REFER TO MOTORCYCLE SERVICE MANUAL DOES ENGINE START NO YES DOES ENGINE STOP OR DROP CYLINDER AFTER SEVERAL MINUTES OF RUNNING NO YES
Download Pdf Manuals
Related Search