Installation Instructions: S&S® IST® Ignition System
Contents
1. YOSNAS 14NIVIIANWILOVWIH CLOL SS N d SINIONI 88 WW NIML eNOSGIAWG AATaWH 0 666L LIM NOILVTIVLSNI 12 9 11 LS ISNI enig XX XX 309 adas T L ooo om fay edinS 1000 L 01901 21 ya A9 N9n Ob 6 K I A L Mya r JEA 1 LE Ad or sg 6 AS N9I1 e 38 4 A 0 38 AVEO yal 9 ul S ya MNHA WAT Wy 1 I y IO a Mon Wu 8 N 39 M Nd M M SI ONId 151 088 NIML 00Z 666L 1101 95 N d SSINYVH 5 aja m L NOM4 102 91 3NON3 MOHO ZZ GNNOYS SISSVHO 6L NOLLNO 8 osetr ANN vaya 3009 NUNIY YJOSN3S yz TWNOIS ANVIO SZ TWNOIS ANVIO 4g dn 100z SSA TWNOIS VO EL TWNOIS L YOSNS e YOON Of YOON St dial 3NION3 6Z NUNIY YOSNIS 8 132. Start installation when you are fresh Be sure all federal state and local laws are obeyed with the installation For optimum performance and safety and to minimize potential damage to carb or other components use all mounting hardware that is provided and follow all installation instructions Motorcycle exhaust fumes are toxic and poisonous and must not be breathed Run motorcycle in a well ventilated area where fumes can dissipate IMPORTANT NOTICE Statements in this instruction sheet preceded by the following words are of special significance A WARNING Means there is the possibility of injury to yourself or others CAUTION Means there is the possibility of damage to the part or motorcycle NOTE Other information of particular importance has been placed in italic type S amp S recommends you take special notice of these items WARRANTY All S amp S parts are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of twelve 12 months from the date of purchase Merchandise that fails to conform to these conditions will be repaired or replaced at 5855 option if the parts are returned to us by the purchaser within the 12 month warranty period or within 10 days thereafter In the event warranty service is required the original purchaser must call or write S amp S immediately with the problem Some problems can be rectified by a telephone call and need no further course
3. also offers a way for trouble codes to be cleared immediately after a fault has been corrected rather than the 50 on off cycles if the key that are normally required q w Note position of connector lock Picture 11 Picture 12 For more details visit http www sscycle com software guardian NOTES Before purchasing the S amp S IST Guardian Diagnostic System P N 55 5075 note that the software is only compatible with Windows 2000 XP Vista 7 32 bit systems It will not work on 64 bit operating systems Also be aware that the Guardian system is only compatible with the S amp S IST ignition module It will not work with stock Harley Davidson or other aftermarket modules 10 Lamp Code Code Reader Only 11 318VN3 NOILINDI 41DNV NOLLVTIVLSNI HLIM A3ANTONI LON SUA TORE ONENG IPT MALIWIT AJY NIDIVI88 M 31nGON ZZL SS ia Niazi vta AAA AJY FINGOW INIDNI SNOISSIW3 ZZZL SS ANYVH JIDA LON NIVW z YIMOd FINGOW SssaNt 3A28O1O EP JINGOW LANYVW H314V LZZL SS SN d JINGOW NOLLINDI LSI 30097 1 NWDS VIVO 1 YOSNAS LAVHSYNVED STAGOW 000 66 JOSNIS LIVHSWVD Nid ZL HDS LNAC E gt SSINYVH JTDADYOLOW NIVW 2 2 dvW 3905534 3111059 d1O4JINVW LA ZLOL SS N d INIWIOVId38 did WOW SSINIVH 267 901 N d INIWIOVId38 YOSNAS ADONA VLOL SS N d LN3IW3DV 1dat
4. amp S Cycle is not associated with Harley Davidson Inc SAFE INSTALLATION AND OPERATION RULES Before installing your new S amp S part it is your responsibility to read and follow the installation and maintenance procedures in these instructions and follow the basic rules below for your personal safety Gasoline is extremely flammable and explosive under certain conditions and toxic when breathed Do not smoke Perform installation in a well ventilated area away from open flames or sparks If motorcycle has been running wait until engine and exhaust pipes have cooled down to avoid getting burned before performing any installation steps Before performing any installation steps disconnect battery to eliminate potential sparks and inadvertent engagement of starter while working on electrical components Read instructions thoroughly and carefully so all procedures are completely understood before performing any installation steps Contact S amp S with any questions you may have if any steps are unclear or any abnormalities occur during installation or operation of motorcycle with a S amp S part on it Consult an appropriate service manual for your motorcycle for correct disassembly and reassembly procedures for any parts that need to be removed to facilitate installation Use good judgment when performing installation and operating motorcycle Good judgment begins with a clear head Don t let alcohol drugs or fatigue impair your judgment
5. as codes memory There are two methods of retrieving trouble codes stored in memory First by counting Flash Codes generated by the Check Engine light see note and second by using the S amp S IST Guardian Diagnostic System P N 55 5075 connected to the data link connector of the S amp S Ignition Wiring Harness Flash codes allow the mechanic to access the trouble code information without the use of the Guardian system but are less detailed Steps for using both methods are outlined below NOTES If the motorcycle has a check engine light this can be used to read stored codes For motorcycles without an OEM check engine light there is an LED on the face of the ignition module that functions as a check engine light and can also be used to read stored codes Trouble codes are stored in memory for as long as the fault exists and for 50 on off cycles of the key after a fault is corrected The S amp S IST Guardian Diagnostic System P N 55 5075 has code clearing capability and is way to clear trouble codes immediately after a fault has been corrected If a fault still exists anew trouble code will be generated Before purchasing the S amp S IST Guardian Diagnostic System P N 55 5075 note that the software is only compatible with Windows 2000 XP Vista 7 32 bit systems It will not work on 64 bit operating systems Also be aware that the Guardian system is only compatible with the S amp S IST ignition module It will not work
6. factory with a single fire ignition The stock coil has a small 3 connector plug If a Twin Cam 88 motorcycle is equipped with the OEM coil there is no need to change it If the bike was previously customized the ignition may have been changed Verify coil type per below Ignition Coil Identification Dual Fire Coil In addition to the spark plug terminals an aftermarket dual fire coil will have two wiring terminals positive negative Single Fire Coil In addition to the spark plug terminals an aftermarket single fire coil will have three wiring terminals A negative terminal for the front cylinder a common 12v terminal and negative terminal for the rear cylinder this is the most common type of single fire coil All single fire coils are compatible with the 585 ignition if they have a resistance of 5 to 3 ohms Coils with higher resistance will decrease ignition output The S amp S Ignition system will also support a variety of different ignition coil combinations as long as they are connected for single fire operation and yield a final resistance of 5 to 3 ohms The ignition is also compatible with dual plug heads with the correct coil configuration Examples of custom coil spark plug combinations supported by the S amp S ignition One coil single fire for single plug heads One coil single fire for dual plug heads e Two coil single fire for single plug heads Two coil single fire for dual plug heads Spark Plug
7. is present install the Knock Sensor there See Step a below If the threaded hole is not present use Location 2 Location 2 Top motor mount at the rear cylinder head attachment point All Twin Cam 88 heads and some early S amp S heads do not have the unused threaded hole across from the temperature sensor and must use the top motor mount location See Step b below a Knock sensor mounting at Location 1 Rear cylinder head 1 Remove the plug from the rear head 2 Insert the 346 x 1 2 coarse thread bolt I through the lock washer m knock sensor g and Y thick spacer h 3 Attach this assembly to the rear head and torque to 11 ft lb See Picture 6 below left b Knock sensor mounting at Location 2 Top motor mount location 1 Remove rear motor mount bolt from rear cylinder head 2 Test fit knock sensor mounting block to rear motor mount location using 3 x 2 coarse thread bolt k and 3 lock washer n Test fit knock sensor to mounting block i using bolt j and lock washer m See Picture 7 below right ics E F z Picture 6 Picture 7 Carefully place fuel tank back into position to check Knock Sensor and mounting block clearance Position the mounting block so that the Knock Sensor or mounting block does not contact the fuel petcock or any other part of the motorcycle If the wiring harness or outer body of the Knock Sensor black plastic portion contacts the eng
8. on and set off run switch to run but do not start engine f The check engine light will flash through its initial start sequence as described above g After the initial sequence of flashes stored trouble codes will then be sent out as a series of flashes Trouble codes are stored as two digit numbers The first digit of the trouble code is equal to the number of times the light flashes There is then a 1 2 second pause then the second digit of the trouble code is flashed again equal to the number of times the light flashes After three seconds if additional codes are stored they will flash in the same manner until all codes have been displayed then the sequence will repeat continuously If only one code is stored it will repeat continuously Example After flashing the initial start sequence as described above there will be a pause then flash flash flash flash 1 2 second pause flash 3 second pause then the sequence repeats This indicates code 41 meaning there is a problem with the crank position sensor NOTE See chart on page 11 for definitions of fault codes supported by the S amp S ignition module h After retrieving codes turn ignition key and run switch to off i Remove jumper wire and replace datalink connector plug 3 Retrieving codes using the S amp S IST Guardian Diagnostic System P N 55 5075 The Guardian system offers a more detailed decsription of the trouble codes than the Flash Code method It
9. Instruction 51 1136 11 11 11 Copyright 2009 2010 2011 by S amp S Cycle Inc All rights reserved Printedin the U S A SES Cycle Tuc 14025 Cty Hwy G PO Box 215 Viola Wisconsin 54664 Phone 608 627 1497 Fax 608 627 1488 Technical Service Phone 608 627 TECH 8324 Technical Service Email sstech sscycle com Website www sscycle com Installation Instructions S amp S IST Ignition System For All 1999 03 Carbureted Harley Davidson Twin Cam 88 Engines Part Number 55 1221 DISCLAIMER S amp S parts are designed for high performance closed course racing applications and are intended for the very experienced rider only The installation of S amp S parts may void or adversely affect your factory warranty In addition such installation and use may violate certain federal state and local laws rules and ordinances as well as other laws when used on motor vehicles used on public highways especially in states where pollution laws may apply Always check federal state and local laws before modifying your motorcycle It is the sole and exclusive responsibility of the user to determine the suitability of the product for his or her use and the user shall assume all legal personal injury risk and liability and all other obligations duties and risks associated therewith The words Harley Harley Davidson H D Sportster Evolution and all H D part numbers and model designations are used in reference only S
10. avidson and other American v twin motorcycles S amp S shall have no warranty or liability obligation if an S amp S part is used in any other application Instruction Contents A Qm mone CAUTION Introduction Parts List Removal of Existing Ignition Module S amp S System Installation Initial Starting and Operation Procedure Basic Troubleshooting Advanced Troubleshooting Do not use a dual fire coil with the S amp S ignition module This kit will NOT work with vehicles equipped with flat slide carbs open primaries and dry clutches If you want to use IST with these configurations contact S amp S we can help set up IST Introduction The Intelligent Spark Technology system uses a sophisticated computerized ECU module that integrates data from sensors that other ignition systems are not designed to use The S amp S system makes use of crank position sensor cam position sensor if present MAP sensor cylinder head temperature sensor and an exclusive knock sensor that actually detects detonation or knock while the engine runs The knock sensor allows the ECU to automatically adjust ignition timing to eliminate knock whenever it occurs In addition the system remembers the conditions that cause the engine to knock and automatically adjusts ignition timing to prevent it when those conditions reoccur On the other hand when conditions allow for increased ignition timing the system will advance timing as far as possib
11. cted Diagnostics scan tool or harness jumper NOTE The electronics used in the S amp S Ignition System require operation in single fire mode only The S amp S Ignition System cannot be used dual fire mode Dual Fire vs Single Fire Ignition Systems Two types of ignition systems have been used on Harley Davidson motorcycles single or dual fire Dual Fire Dual fire ignitions fire the spark plugs in both cylinders on every stroke each time the pistons reach the tops of the cylinders One piston is at the top of the compression stroke while the other piston is near the top of the exhaust stroke Dual fire is also known as wasted spark because the second spark fires near the top of the exhaust stroke Dual fire was common for many years because of its simplicity and reliability Dual fire has a slightly rougher idle than single fire because the wasted spark occurred just after the top of the exhaust stroke of the rear cylinder disrupting the incoming intake charge Single Fire Single fire ignitions fire the spark plugs on every other stroke of the engine only at the top of the compression stroke One cylinder fires then after one crankshaft revolution the other cylinder fires A single fire ignition system allows the ignition to reliably transmit more power to the coil during the compression stroke when it is needed most All Harley Davidson Twin Cam 88 motorcycles for this ignition application came from the
12. f installed a motorcycle with the VSS routed to the ignition module To insure proper learning of the type of signal used in your application Be sure to start the motorcycle in neutral and on a flat level surface b Allow the engine to run fora minimum of 10 seconds before turning the key off This procedure only needs to be performed once but it should be repeated if the IST module is installed in another motorcycle 2 Initial Operating Procedure Initially the S amp S Intelligent Spark Technology Ignition System operates using a standard ignition timing map that may not be optimum but is considered safe for most engine configurations After 3 to 5 hours of operation with the engine warmed up the IST Ignition System will have adjusted the map to create one that is optimized for the particular engine configuration See Step 2 a The IST system will continually adapt to subsequent changes in riding style fuel quality weather conditions and elevation to further optimize the ignition map For this reason data recorded using a chassis dynomometer should be measured after the system has had sufficient time to learn the specific engine parameters a Ride your motorcycle as you normally would during this initial learning period The IST system will learn and adapt the ignition map to various conditions as they are encountered so the more riding you do the more the system will fine tune itself Below are some suggested practices to
13. help the system quickly create the initial optimized timing map 1 Allow engine to remain at normal operating temperature for at least an hour 2 Ride up hills and or inclines 3 Ride at highway speeds for at least 20 minutes When road conditions are safe briefly 1 2 seconds at a time open the throttle all the Way 4 Ride through intersections stretches of road where second and third gear roll ons are required F Basic Troubleshooting Below are some suggestions if any problems are encountered with the IST Ignition Module 1 Problem Engine cranks but will not start Possible solutions a Check that the gas tank is full and that the fuel petcock is turned on b Check that coil wires plug and harness have been reinstalled properly c Check that all connections are complete on the Harley Davidson Twin Cam 88 Wiring Harness Adapter 2 Problem Key power on switch does not seem to work Possible solutions a Check for blown fuses and or tripped circuit breakers b Check that the battery has been properly reconnected c Check that the 12 pin Black and Grey connectors are connected correctly For example check that the wire colors match from one side to the other If they do not match disconnect the connector rotate it to the correct orientation and reconnect G Advanced Troubleshooting The 5 amp 5 ignition system features advanced self diagnostic capabilities The unit detects operational faults and stores them
14. ine or any other part of the motorcycle it could damage the Knock Sensor or interfere with its ability to detect knock See Picture 8 below left Special care for rubber mounted motors must be given View Knock Sensor while motor runs to make sure it has proper clearance 3 After determining final position for Knock Sensor remove mounting bolts and lockwashers then re install them on mounting block bolt k torque to 33 ft lbs and Loctite 243 on knock sensor bolt j torque to 11 ft lbs J i as 7 Picture 8 Picture 9 Hold knock sensor in position by hand only while torquing Do use pliers Damage to knock sensor will occur 3 Installation of the IST Ignition Module and Wiring Harness Adapter The Wiring Harness Adapter for Harley Davidson Twin Cam 88 See Picture 9 above right is a one piece assembly consisting of the following connectors e a IST Ignition Module Connector 32 Socket Gray Delphi Packard 12129025 Connects to the S amp S Intelligent Spark Technology Ignition Module b amp c Motorcycle Main Harness Connectors 1 12 Pin Gray Deutsch DT04 12PA 1 12 Pin Black Deutsch DT04 12PB Connects to the stock Harley Davidson wiring harness in place of the stock module e d Knock Sensor Connector 2 Socket Bosch 1928403192 e e Head Temperature Sensor Connector 2 Socket Delphi Packard 12162193 NOTE Locking tabs on each con
15. le without causing the engine to knock In effect the system learns the ignition requirements of a particular engine and writes a custom ignition map for it This results in optimized power and fuel economy as well as reduced emissions If ignition requirements change if a lower grade of fuel is introduced for example the system will automatically make the necessary ignition timing changes to avoid detonation and possible engine damage This feature is particularly important in touring applications where the rider sometimes has less control over fuel quality If a different camshaft is installed or if cylinder head modifications are made the S amp S Intelligent Spark Technology system changes the ignition timing for the new configuration Even if major engine modifications are made such as the installation of a stroker or big bore kit the system will adjust to the ignition requirements of the engine Additional features Simple installation installation kits plug into stock wiring harness No timing adjustments the system adjusts timing automatically e Factory pre set 6250 RPM rev limiter Adjustable up to 7200 RPM with S amp S IST Guardian Diagnostic System p n 55 5075 Single fire operation requires two coils or dual coil package High output Automatically maximizes coil output e Automatic dwell adjust will optimize current for any coil 0 5 to 3 ohms e Short circuit and reverse polarity prote
16. nd Knock Sensor Connector d See Picture 9 to the corresponding sensors g Use the provided wire ties to secure this portion of the harness to the motorcycle frame or a portion of the existing harness NOTE If the tank is removed or raised temporarily replace it to insure clearance for the Engine Temperature and Knock Sensor portions of the harness Reroute any wires that may be damaged by installing the tank h Permanently reinstall tank reconnect battery positive cable first and any other portions of the motorcycle that have been removed or disconnected Picture 10 E InitialStarting and Operation Procedure Because the S amp S Intelligent Spark Technology Ignition System is designed to learn the specific engine motorcycle configuration it is being used for the following initial starting and operating procedures must be followed after installing the system for the first time These procedures need to be followed only once After that the motorcycle can be started and ridden as usual 1 Initial Starting Procedure NOTE IMPORTANT On some 2001 and up models the Vehicle Speed Signal VSS is sent to the ignition module in lieu of a cam position signal The module must learn which signal is connected It is important that the rear wheel remain motionless if the key is on the first time the module is installed Until the ignition has learned what type of signal is present it could fire the plugs based on wheel movement i
17. nector listed should produce a light clicking sound when properly assembled S amp S recommends checking each connection by lightly pulling on each half of the connector to insure that the locking tabs have properly seated The IST ignition module includes a hardware packet The hardware is intended for spacing the module and the connector off of the mounting back plate Washers are also included for the mounting screws This hardware is only necessary on some models The hardware packet includes the following spacers and washers e 200 spacers 4 060 spacers 4 475 OD washers 2 e 250 ID lockwashers 2 a Route the wiring harness along the bike frame to ensure that the Ignition Module Connector a See Picture 9 previous page reaches the Module mounting location b Connect the Ignition Module Connector a See Picture 9 to the Module c Install the module using the stock mounting hardware and the S amp S hardware if necessary included with the module d Plug the 12 socket black and gray plugs from the stock Harley Davidson wiring harness into the corresponding gray and black 12 pin Motorcycle Main Harness Connectors b amp c See Picture 9 on the S amp S harness See Picture 10 below e The remaining portion of the harness that connects to the Head Temperature Sensor and the Knock Sensor should be routed along with the stock wiring under the gas tank f Connect the Head Temperature Connector e See Picture 9 a
18. of action A part that is suspect of being defective must not be replaced by a Dealer without prior authorization from S amp S If it is deemed necessary for S amp S to make an evaluation to determine whether the part was defective a return authorization number must be obtained from S amp S The parts must be packaged properly so as to not cause further damage and be returned prepaid to S amp S with a copy of the original invoice of purchase and a detailed letter outlining the nature of the problem how the part was used and the circumstances at the time of failure If after an evaluation has been made by S amp S and the part was found to be defective repair replacement or refund will be granted ADDITIONAL WARRANTY PROVISIONS 1 S amp S shall have no obligation in the event an S amp S part is modified by any other person or organization 2 S amp S shall have no obligation if an S amp S part becomes defective in whole or in part as a result of improper installation improper maintenance improper use abnormal operation or any other misuse or mistreatment of the S amp S part 3 S amp S shall not be liable for any consequential or incidental damages resulting from the failure of an S amp S part the breach of any warranties the failure to deliver delay in delivery delivery in non conforming condition or for any other breach of contract or duty between S amp S and a customer 4 S amp S parts are designed exclusively for use in Harley D
19. on service manual for correct procedure for removing fuel tank and related components 1 Installation of the Cylinder Head Temperature Sensor NOTE The S amp S Cylinder Head Temperature Sensor for mounts in a boss found on the front head of all Harley Davidson Twin Cam 88 engines This boss is used for mounting the Engine Temperature Sensor on fuel injected Harley Davidson Motorcycles On carbureted models the hole is plugged a Remove the plug and install the S amp S Head Temperature Sensor b Tighten the sensor to 10 12 ft lbs using a deep well socket and a torque wrench See Picture 5 next page N A C N 444 2 Installation of the Knock Sensor Kit A CAUTION Knock Sensor must be mounted to the rear cylinder for correct operation Mounting the Knock Sensor on the front cylinder will provide an incorrect signal NOTE There are two mounting locations possible for the knock sensor Read description of each location and then examine your motorcycle for which one to use The first location has better clearance than the second location the knock sensor will work well in either one Location 1 Rear cylinder head across from the temperature sensor on the front head Some S amp S heads have an unused threaded hole in the rear head near the intake port Stock Harley Davidson Twin Cam 88 heads and some S amp S heads do not have the unused threaded hole If the extra threaded hole
20. on Module 1 Locate the ignition module installed on your motorcycle The ignition module can usually be found under the seat or a side cover See Picture 3 below left Refer to the Harley Davidson service manual for your motorcycle if you have trouble locating it 2 Remove the module mounting hardware and unplug the module See Picture 4 below right Each plug is disconnected by simultaneously pressing the locking tabs on the connector and pulling it away from the module Save the mounting hardware for installation of the S amp S ignition module ka 3 Picture 4 S amp S System Installation Be careful not to damage the front of the tank when raising or removing it It is possible to install the ignition knock sensor assembly engine temperature assembly and wiring harness without removing the fuel tank Loosen do not remove the bolt at the front of the tank and remove the mounting bolt s at the rear of the tank The rear of the tank then can be raised slightly allowing enough room to install these components NOTE Clearances are limited at the front of the tank Use care not to damage any painted surfaces while handling tank Installing components without removing the fuel tank is a timesaving suggestion only If there is any reservation on the part of the installing mechanic about performing this installation with the fuel tank in place refer to the appropriate Harley Davids
21. s and Plug Wires Spark plugs must be resistor spark plugs suppression type of the correct style and heat range for the application Do not use non resistor plugs Spark plug wires must be suppression type Do not use solid metal core plug wires B Parts List The S amp S Ignition Installation Kit for 1999 2003 Harley Davidson Twin Cam 88 S amp S 55 1012 See Picture 1 below left is intended only for installation of S amp S Intelligent Spark Technology IST Ignition Module See Picture 2 below right S amp S Ignition System Installation Kit 55 1012 contains the following items See Picture 1 S amp S 55 1017 Wiring Harness Adapter Items a thru e S amp S 55 1014 H D 32446 99 Cylinder Head Temperature Sensor Item f S amp S 55 1015 Knock Sensor Kit Items 9 thru n e Loctite Wire Ties Items o and All reference to Harley Davidson part numbers is for identification purposes only We no way are implying that any of S amp S Cycle s products are original equipment parts or that they are equivalent to the corresponding Harley Davidson part number shown S amp S Intelligent Spark Technology ECU Module Picture 1 Picture 2 C Removalor Existing Ignition Module Prior to installation disconnect and remove the battery negative cable first This will eliminate potential sparks and inadvertent engagement of the starter while working on the motorcycle C Removal of Existing Igniti
22. with stock Harley Davidson or other aftermarket modules 1 Overview of check engine light operation Initial power on sequence The check engine light will flash in one of the three ways listed below each time the key is turned on and the off run switch is set to run If no faults are detected the IST ignition will turn the check engine light on for 4 seconds then off If a fault is present at that time the check engine light will turn on for four seconds then turn off for four seconds then turn on continuously If a fault has occurred and been corrected within the past 50 key on off cycles the check engine light will turn on for four seconds then off for four seconds then on for eight seconds then off When a current fault is detected a code is stored in memory and the check engine light comes on continuously 2 Retrieving and displaying codes using the Check Engine light a Turn key and off run switch to off b Remove seat or side cover to expose the OEM datalink connector located near the ignition module See Picture 11 next page c Remove rubber plug from OEM datalink connector d Connect pins 1 and 2 of the datalink connector with a jumper wire Pins have to remain jumped together during the code retrieval process See Picture 12 next page for pin locations Do not connect any other pins except pins 1 amp 2 e Turn key to
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