Mallory Ignition ACCEL Ignition 35496 - Manual

ACCEL IGNITION www.accel-ignition.com 1
Ignition Model #35496
FORM 97140090
INSTALLATION INSTRUCTIONS
OVERVIEW
ACCEL Ignition Model 35496 is intended for use with Harley-Davidson®
Evolution® type motorcycle engines. The Model 35496 replaces the origi-
nal 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.
The Model 35496 offers adjustable advance, adjustable RPM limit set-
tings 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.
AVOIDING HEAT RELATED FAILURES
Heat kills electronics. The Model 35496 uses electronic devices rated
for operation at 105 deg C (221 deg F), the highest rating available. The unit
can tolerate somewhat higher temperatures, but exposure to tempera-
tures 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 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:
• 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.
• Improper carburetor jetting resulting in lean air/fuel ratio (AFR). A lean
AFR will cause the engine to run very hot. All performance engine
modifications necessitate carburetor rejetting. Carburetors are never
correctly jetted out-of-the-box. The only practical means of cor-
rectly jetting a carburetor is to test the motorcycle on a chassis dyno
equipped with an exhaust gas sniffer.
• Lack of an oil cooler on a 95 CID or larger engine.
• Exhaust pipe without heat shield in close proximity to the nose cone. If
any of the above applies to your application, the Model 35496 may be
exposed to excessive temperatures resulting in reduced life expec-
tancy. Use an infrared thermometer to check the module temperature.
INCLUDED AND ADDITIONAL REQUIRED PARTS
All units include a parts bag with crimp terminals for coil and VOES
hookup.
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 breaker
points will require H-D® timing rotor P/N 32402-83 or an equivalent after-
market part.
CAUTION: CAREFULLY READ INSTRUCTIONS BEFORE PROCEEDING. NOT LEGAL FOR USE OR SALE ON POLLUTION CONTROLLED VECHICLES
INSTALLATION
1. Turn off the ignition switch and disconnect the battery
ground cable before proceeding.
2. Refer to Figure 1. Remove gear case cover plate and mount-
ing 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.
3. 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.
4. Install the Model 35496 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®.
5. 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.
6. Route the wiring harness along the side of the unit 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.
Figure 1 - Feeding Harness Through Exit Hole