Model 1005 Installation Instructions
Contents
1. r Twin Installation Instructions for Ignition Model 1005 CAUTION CAREFULLY READ INSTRUCTIONS BEFORE PROCEEDING NOT LEGAL FOR SALE OR USE IN CALIFORNIA OR ON ANY POLLUTION CONTROLLED VEHICLES OVERVIEW Twin Tec ignition Model 1005 is intended for use with Harley Davidson Evolution type motorcycle engines The Model 1005 replaces the original equipment OE electronic ignition system on 1978 99 models The unit mounts in the gear case cover and uses the standard H D timing rotor It can also be used on earlier models with breaker points and mechanical advance Please note that the 1005S EX is recommended for 1998 and later Sportster models as it mates directly with the OE wiring harness The Model 1005 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 and other engine parameters such as rear cylinder timing offse2. Model 1005 MODE SETTINGS FOR SINGLE FIRE 2 STREET ADVANCE CURVES MULTI SPARK DISABLED 3 STREET ADVANCE CURVES MULTI SPARK ENABLED 6 RACE ADVANCE CURVES MULTI SPARK DISABLED 7 RACE ADVANCE CURVES MULTI SPARK ENABLED 9 RACE ADVANCE CURVES KICK START RECOMMENDED TIMING SETTINGS Street and race advance curve families are shown in Figures 6 and 7 Each family has minimum and maximum curves The advance slope switch allows you to run an advance curve in between these minimum and maximum 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 Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 386 304 0700 www daytona twintec com SINGLE FIRE COIL WHITE BLACK TO FRONT SPARK PLUG TO REAR SPARK PLUG WEATHER PACK CONNECTORS FEMALE MALE TERMINAL OPTIONAL CABLE CONNECTED TO BROWN TACH WIRE DURING PC LINK Tuning a particular engine setup always 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 stock engines run on normal pump gas 87 89 octane use the street advance curves and advance slope setting 5 For stock or mildly modified engines run on 92 or higher octane gas use the
3. RPM limit cylinder firing is always paired This eliminates a torque couple and results in very smooth operation compared to random or sequence 3 type RPM limiters Set a safe RPM limit that is appropriate for your engine Most Evolution engines with OE valvetrain components should not be run over 5 700 RPM STATIC TIMING PROCEDURE 1 Timing marks are located the flywheel and may be viewed by unscrewing the inspection hole plug Most engines will have both TDC and advance 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 The precise timing procedure is based on using the 35 BTDC timing mark and race maximum advance curve with VOES grounded that reaches 35 BTDC around 2 000 RPM refer to Figure 7 To use this procedure you must have a VOES switch connected If a VOES switch is not used you must ground the purple white wire while setting the timing Set mode switch to 4 for dual fire or 6 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 just over 2 000 RPM Rotate the ignition to center the 35 BTDC timing mark in the inspection hole Tighten standoffs and verify that the timing h
4. Switch setting 9 is available on revision 8 3 and later units revision is labeled on back of unit and selects race advance curves single fire and kick start mode Multi spark is disabled Figure 4 Dual Fire Wiring Diagram ENGINE STOP RUN SWITCH OPTIONAL VOES VACUUM SWITCH PURPLE WHITE TAPE UP WIRE IF VOES NOT USED MODE 3 RPM LIMIT SLOPE X1000 100 CG 3 0 3 0 3 CB CG 0 0 Ep 12 oe 25 ihe 5 BY status vos TwinTec Internal Ignition Model 1005 MODE SETTINGS FOR DUAL FIRE STREET ADVANCE CURVES MULTI SPARK DISABLED 1 STREET ADVANCE CURVES MULTI SPARK ENABLED 4 RACE ADVANCE CURVES MULTI SPARK DISABLED 5 RACE ADVANCE CURVES MULTI SPARK ENABLED Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 386 304 0700 www daytona twintec com WHITE BLACK DUAL FIRE COIL TO FRONT SPARK PLUG WHITE BLACK TO REAR SPARK PLUG BLUE WIRE USED FOR SINGLE FIRE ONLY TAPE UP OPTIONAL CABLE CONNECTED TO BROWN TACH WIRE DURING PC LINK TO PC SERIAL PORT FEMALE TERMINAL MALE TERMINAL WEATHER PACK CONNECTORS Model 1005 5 2015 Page 4 Figure 5 Single Fire Wiring Diagram ENGINE STOP RUN SWITCH OPTIONAL VOES VACUUM SWITCH PURPLE WHITE TAPE UP WIRE IF VOES NOT USED MODE ADVANCE RPM LIMIT SELECT SLOPE 1 1000 100 23 gre 23 23 Ss SDs Os BY status voes TwinTec Internal Ignition
5. and causes the Twin Tec module to generate additional timing advance The green VOES LED illuminates whenever the VOES input is active timing advanced Refer to the Evo Tech FAQ on our website for more VOES information The use of a VOES is required for proper operation of the Twin Tec module If your motorcycle did not include an OE VOES you can use H D VOES P N 26566 91 for stock or mildly modified engines For high performance engines we recommend our P N VOES KIT MGC7 This is a complete kit with mounting bracket and has a higher vacuum switching level 6 7 inch Hg that helps eliminate spark knock under light load or throttle roll on 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 1005 PC Link Evo for programming custom advance curves and other engine parameters and Operating Statistics for viewing engine operating data 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 Model 1005 5 2015 Page 8 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
6. battery ground cable Complete the setup and timing procedures given on pages 3 7 12 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 OPERATING MODES A single 10 position rotary switch is used to select the operating mode Switch settings are as follows 0 Street advance curves dual fire multi spark disabled Street advance curves dual fire multi spark enabled Street advance curves single fire multi spark disabled Street advance curves single fire multi spark enabled Race advance curves dual fire multi spark disabled 1 2 3 4 5 Race advance curves dual fire multi spark enabled 6 7 8 9 9 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 Race advance curves single fire multi spark disabled plug with silicone RTV and use it as protective Race advance curves single fire multi spark enabled cover Use a proper Weather Pack crimping tool or solder the terminals Pioneer Standard Boot load mode factory use only see text www p
7. front piston comes up on TDC For static timing you must rotate the crankshaft so that the front piston is at TDC on the compression stroke Remove spark plugs and rotate crankshaft If you place your thumb over the spark plug hole you will feel pressure as the piston comes up on the compression stroke Continue rotating the crankshaft until the TDC mark is precisely centered in the inspection hole Ground the spark plug cables to avoid a shock hazard You can use small jumper wires with alligator clips for this purpose Turn on the ignition switch The red LED is used as 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 the unit clockwise until the LED goes out Note that the LED goes out at TDC Tighten the standoffs to secure the unit Turn off the ignition switch and reinstall the spark plugs exhaust gas sniffer or use our WEGO PRECISE TIMING PROCEDURE 1 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 2 5 700 RPM Inadvertent settings below 3 000 RPM are ignored and result in a 3 000 RPM limit The Model 1005 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
8. 8014 are required to program the retard feature Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 386 304 0700 www daytona twintec com TROUBLESHOOTING FLOWCHART Follow the troubleshooting 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 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 Model 1005 5 2015 Page 9 Troubleshooting Flowchart STARTING POINT DID THE ENGINE RUN PROPERLY BEFORE INSTALLATION OF THE TWIN TEC MODULE TURN IGNITION ON SET ENGINE SWITCH TO RUN CRANK ENGINE DOES RED STATUS LED FLASH REPAIR UNDERLYING PROBLEM BEFORE INSTALLING TWIN TEC MODULE REFER TO MOTORCYCLE SERVICE MANUAL DOES ENGINE START NO YES 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 DOES ENGINE STOP OR DROP CYLINDER AFTER SEVERAL MINUTES OF RUNNING NO YES REPLACE COIL DOES ENGINE MISFIRE IS PROBLEM FIXED CHECK FOR LOW BATTERY NO FUEL OR FOULED SPA
9. RK PLUGS YES NO ANY OBVIOUS FAULT FOUND NO YES REPLACE TWIN ves No DONE TEC MODULE CORRECT FAULT CHECK FOR MINIMUM 13V AT COIL WITH ENGINE RUNNING AT 2000 RPM IS VOLTAGE OK SINGLE FIRE ONLY INSTALL POWER YES NO RELAY KIT CALL TECH SUPPORT FOR DETAILS IS PROBLEM FIXED INSTALL POWER RELAY YES NO KIT CALL TECH SUPPORT FOR DETAILS DONE REPLACE SPARK PLUGS SPARK PLUG WIRES AND COIL IS PROBLEM FIXED REPLACE COIL YES NO IS PROBLEM FIXED REPLACE TWIN YES i DONE TEC MODULE REPLACE TWIN BONE TEC MODULE DOES ENGINE MISFIRE AT PART THROTTLE OR WHILE COLD NO YES FOR MISC PROBLEMS CHECK FOR INCORRECT CARB CALL TECH SUPPPORT JETTING OR INTAKE LEAK IS PROBLEM FIXED YES NO REPLACE TWIN DONE TEC MODULE Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 Model 1005 386 304 0700 www daytona twintec com 5 2015 Page 10
10. ackard pios com sells Packard crimping Race advance curves single fire kick start see text tool P N 12014254 Snap on sells a low cost tool P N PWC30 The engine will not run if the mode switch setting 10 Single Fire Tach Hookup If your motorcycle had does not match the wiring hookup i e you cannot a tach before installation of the Twin Tec module select single fire mode with a dual fire coil hookup the tach was connected to the pink coil wire When you connect the tach direct to the Twin module Advance curve families are shown in Figures 6 as shown in Figure 5 for a single fire application and 7 Use the street advance curves mode switch you must make sure that it is not still connected to settings 0 3 for stock or mildly modified engines Use Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 Model 1005 5 2015 Page 3 the race advance curves mode switch settings 4 7 for high compression engines 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 setting 8 is a factory reserved setting used for a special boot load mode that allows loading an entirely new program into the processor FLASH memory
11. and install the mounting standoffs as shown in Figure 3A for Big Twin or 3B for Sportster models Do not fully tighten the standoffs or install the outer cover plate until after the static timing procedure Route the wire harness along the frame tubing to the ignition coil Make sure that the harness is clear of hot exhaust areas and cannot chafe against sharp edges Secure the harness with nylon cable ties Model 1005 5 2015 8 Japon a ERL 3 D wn 530 57115 Refer to the appropriate wiring diagram Use the dual fire hookup shown in Figure 4 if you have an OE coil or other coil with two primary terminals Use the single fire hookup in Figure 5 if you are installing an aftermarket coil with three primary terminals Use appropriate crimp terminals for coil and VOES hookup With the exception of the tachometer and rear coil section single fire only standard H D wire color codes are used Tape up any unused wires CAUTION Engine damage from excessive timing advance may result if the purple white VOES wire is inadvertently shorted to ground 386 304 0700 www daytona twintec com 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 the pink coil wire Trace the wire going all the way back to the tach to avoid an inadvertent coil connection 11 Reconnect the
12. as not changed When done change mode and advance slope switches back to desired values Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 Model 1005 386 304 0700 www daytona twintec com Page 6 5 2015 Figure 6 Street 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 7000 ENGINE RPM Figure 7 Race Advance Curves 40 6 wo ADVANCE DEG N ak MAX ADVANCE AT WIDE OPEN THROTTLE MIN ADVANCE AT WIDE OPEN THROTTLE 5 O MAX ADVANCE WITH VOES GROUNDED O MIN ADVANCE WITH VOES GROUNDED 02 0 1000 2000 3000 4000 5000 6000 7000 Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 Model 1005 386 304 0700 www daytona twintec com 5 2015 Page 7 Figure 8 Front Cylinder Timing Marks EARLY STYLE LATE STYLE 1996 AND LATER 1995 AND LATER EXPORT Mo TDC 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
13. cations necessitate carburetor rejetting Carburetors are never correctly jetted out of the box The only practical means of correctly jetting a carburetor is to test the motorcycle on a chassis dyno equipped with an exhaust gas sniffer or to use our WEGO system e Lack of an oil cooler on a 95 CID or larger engine e Exhaust pipe without heat shield in close proximity to the nose cone If any of the above applies to your application the Model 1005 may be exposed to excessive temperatures resulting in reduced life expectancy Use an infrared thermometer to check the module temperature Can you also our Operating Statistics software to monitor temperature levels If excessive temperatures are encountered and cannot be remedied you should consider using an external module such as our Model 1006 or 1007 INCLUDED AND ADDITIONAL REQUIRED PARTS All units include a parts bag with crimp terminals for coil and VOES hookup and a Packard Weather Pack connector set intended for installation on the tachometer wire to provide an access point for the PC link FL series Big Twin models manufactured prior to 1985 FX series Big Twin and XL Series Sportster models manufactured prior to 1984 all Sportster 1200S models and all models with original equipment Model 1005 5 2015 Page 1 breaker points will require H D timing rotor P N 32402 83 or an equivalent aftermarket part INSTALLATION 1 Turn off the ignition switch an
14. d disconnect the battery ground cable before proceeding Refer to Figure 1 Remove gear case cover plate and mounting hardware You may have to drill out two rivets that hold the cover reassemble with supplied self threading screws Remove the sensor plate or breaker points Make sure that the correct H D P N 32402 83 timing rotor is installed Figure 1 Feeding Harness Thru Exit Hole You can completely remove the OE ignition harness and external module 1980 and later models if desired However you must disconnect all OE wires from the coil except the white black wire from the engine stop run switch Install the Model 1005 unit Wrap one turn of electrical tape around the end of the protective wire harness sleeve This will compress the sleeve and allow you to easily feed it through the cable exit hole in the gear case cover The tape will also keep the sleeve end from fraying You will have to enlarge the hole with a drill on early models and some Sportsters Rotate the unit and then place it into position as shown in Figure 2 Be careful to avoid damage to the black plastic Hall Effect sensors on the bottom of the unit Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 386 304 0700 www daytona twintec com MODE ADV RPM SEL SLOPE MAG BY STATUS a VOES gt TwinTec Internal Ignition Modal 1005 Route the wiring harness along the side of the unit
15. 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 KICK START APPLICATIONS Model 1005 units are preset at the factory with a two revolution cranking delay that is optimum for electric start applications This cranking delay precludes kick starting Model 1005 units manufactured starting January 2006 can be programmed for kick start mode Twin Tec PC Link Evo software and USB interface cable P N 18014 are required to program kick start mode The mode switch can also be used to select single fire kick start mode on revision 8 3 and higher Model 1005 units refer to page 3 for details USE OF VOES INPUT FOR RETARD The Twin Tec module can be programmed to allow alternate usage of the purple white VOES wire as a retard input If this feature is enabled the unit will retard timing up to 10 degrees when the purple white wire is grounded This retard feature is useful for turbocharger or nitrous oxide injection applications Twin Tec PC Link Evo software and USB interface cable P N 1
16. street advance curves and advance slope setting 7 Model 1005 5 2015 Page 5 For high compression engines use the race advance curves and advance slope setting 2 You can adjust the initial timing by rotating the Twin Tec module relative to the gear housing clockwise rotation increases initial timing If you experience spark knock only at low RPM you can try reducing the initial timing while maintaining an aggressive advance slope for maximum power at high RPM by increasing the advance slope switch setting If spark knock is a problem at high RPM decrease the advance slope switch setting Once you have determined the best switch settings you can further optimize the timing at a particular RPM by programming a custom advance 3 curve with our PC Link software and optional cable Note that the wide open throttle WOT curves are active unless the VOES input is grounded During 4 idle and cruise the VOES input is grounded green VOES LED illuminated and the low manifold pressure MAP curves are active TUNING TIP Lean air fuel ratio AFR increases the tendency for spark knock Check AFR and rejet carburetor before optimizing ignition timing Test the motorcycle on a dyno with an timing marks for the front cylinder as shown in Figure 8 If you are not sure refer to your shop manual You can also identify the TDC mark by removing the spark plugs and rotating the crankshaft turn rear wheel in high gear until the
17. t The use of the tachometer wire for the PC link eliminates the need to remove the outer cover plate All Model 1005 units log engine operating data that may be downloaded and viewed with our Operating Statistics software Model 1005 units manufactured starting January 2006 include a build in temperature sensor and logging of temperature data AVOIDING HEAT RELATED FAILURES Heat kills electronics The Model 1005 uses electronic devices rated for operation at 105 deg C 221 deg the highest rating available The unit can tolerate somewhat higher temperatures but exposure to temperatures above 125 deg C 257 deg F will greatly reduce life expectancy We sometimes see problematic applications where several module failures have occurred The failure mode is a classic thermal Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 386 304 0700 www daytona twintec com intermittent where the module stops firing one cylinder when it gets hot We have found that these problematic applications share one or more of the following characteristics e VOES switch removed or non functional All street driven engines require vacuum advance Without vacuum advance at idle and part throttle thermodynamic efficiency is reduced and engine temperatures increase significantly e Improper carburetor jetting resulting in lean air fuel ratio AFR A lean AFR will cause the engine to run very hot All performance engine modifi
18. 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 CAUTION Do not use solid copper spark plug cables or non resistor type spark plugs The unit may misfire The Twin Tec module is compatible with all modern ground sensing type tachometers including H D OE and Autometer 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 trigger pulse In this case you will require a commercially available tachometer adapter 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 Most 1980 and later motorcycles are equipped with a OE VOES Without vacuum advance at idle and part Daytona Twin Tec LLC 933 Beville Road Suite 101 H S Daytona FL 32119 386 304 0700 www daytona twintec com 20 BTDC NOT USED 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
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