Crane HI-4E - Nightrider.com
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1. mn GROUND PINK IGNITION SPARK FRONT COIL PLUGS 5 COIL O COIL A 12V COIL S ADDED 18 AWG JUMPER FROM 0 COIL TO COIL A REAR REAR oo IGNITION SPARK L WHITE COIL PLUGS REAR TACHOMETER a LO NESTA 3 99 7 9000 3100A Check for low voltage from a faulty or marginal charging system and battery CHECKING FOR SPARK WARNING Never crank the engine with any spark plug wire disconnected 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 alligator 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 MISFIRE OR OPERATION Field experience has shown that popping back through the carburetor mistiring and intermittent failure especially after the engine gets hot are usually not caused by electrical problems within the HI 4E Carburetor problems fouled spark plugs coil failure and loose wire harness connections are the most common cul prits Verify that spiral core or suppres sion type spark plug wires and resistor spark plugs are being used INTERMITTENT TACH INOPERATIVE If the tach is inopera tive after installation of the HI 4E in single fire mode you may require a tach adapter The HI 4E tach output is com patible with ground sensing tachs which includes most O E and aftermarket tachs Some tachs reguire a high2. or higher may be used but may not produce optimum output We recommend the following coils for single and dual plug applications Dual Fire Mode With Single Plug Heads You can retain the O E coil For increased ignition energy we recommend the Crane 8 3006 or 8 3002 coils Single Fire Mode With Single Plug Heads Use Crane 8 3001 coil This is a Siamese coil with two independent sec tions and will fit in the stock mounting location on most H DO motorcycles Single Fire Mode With Dual Plug Heads Use two Crane 8 3006 or 8 3002 coils You will have to fabricate a bracket to mount the second coil Crane FireWire spiral core spark plug wires or equivalent sup pression wires are recommended for best performance Do not use non suppression solid core spark plug wires they may cause interference with your ignition system and accessories Use resistor suppression type spark plugs Non resistor spark plugs may cause interference with the computer in the HI 4E INSTALLATION ON LATE MODELS WITH 7 OR 8 PIN PLUG 1 Turn ignition switch off and disconnect battery ground cable 530 Fentress Boulevard Daytona Beach FL 32114 Tech Line 904 258 6174 Check our web site for updates www cranecams com Fax 904 258 6167 3 99 9000 3100A FIGURE 1 H D 1980 AND LATER O E IGNITION SYSTEM SCREWS 2 13 TIMING ROTOR 17 SPARK PLUG WIRES 2 WASHERS 2 14 GEAR CASE COVER 18 VACUUM OPERATED ELECTRICAL SWITCH VOES
3. 500 RPM Rear cylinder timing offset This feature allows slight offset of rear cylinder timing for critical race applications and dyno tuning The offset range is 5 to 4 degrees The offset function works in both dual fire and single fire modes since the HI 4E knows which cylinder is fir ing Normally the rear cylinder offset switch should be set to zero 5 Option setup The four position DIP switch at the left of the unit is used for option setup The top position is used to select single or dual fire You must select dual fire mode if you do not hookup a single fire coil The 2nd switch position selects the advance curve The 3rd switch position selects kick start or electric start mode Do not use kick start mode on engines with an electric starter The bottom switch position selects single or multi spark mode Multi spark mode is recommended for optimum performance in most applications Some late model engines with very lean carburetor jetting may exhibit excessive spark knock in multi spark mode 9000 3100A 6 Timing LED This can be used for static timing and as a diagnostic aid The LED should light up when the igni tion key is turned on The timing LED will go off when the crankshaft is rotated past TDC During cranking the LED will blink SINGLE FIRE HOOKUP Refer to Figure 3 for hookup with single plug heads Refer to Figure 4 for hookup with dual plug heads In either case you must connect the Weather Pack c
4. ENGINE WILL NOT START Check that timing LED lights up when ignition key is first turned on If not check for 12 volts on white wire to COIL Check that timing LED blinks while engine is cranked If not camshaft position sensor or HI 4E may be defective If the timing LED blinks but engine will not start recheck all wire harness connections or replace coil s 9000 3100A CAM POSITION SENSOR FIGURE 3 H D SINGLE FIRE IGNITION HOOKUP FOR lt 32400 80A SINGLE PLUG HEADS TRIGGER ROTOR 32402 83 BLACK WHITE RED AND GREEN Y VOES BLACK BLACK GROUND REAR 7 CYLINDER f 3 Bal Vx CBS HI IGNITION Model 8 31 00 7 OR 8 PIN PLUG lt BROWN TACH a WHITE PURPLE WHITE N WHITE REAR COIL 12V NU A BLACK IGNITION 12 VOLT A GROUND WHITE SWITCH BATTERY 7 12V CRANE 8 3001 SINGLE FIRE COIL FRONT SPARK TACHOMETER PLUGS J 3 99 9000 3100A FIGURE 4 H D SINGLE FIRE IGNITION HOOKUP FOR DUAL PLUG HEADS ent ES TON Pa TRIGGER ROTOR o 32402 83 VOES 32400 80A BLACK BLACK GROUND BLACK WHITE RED AND GREEN K ua 7 R EAR oa Ole JI HI 4E ereBall Hi PURPLE WHITE Mo del g 31I00 oo CEASE 7 OR 8 PIN PLUG IGNITION vuon SWITOH BATTERY 7 BROWN TACH WHITE 12V 12V COIL o 1 AG FRONT FRONT BLACK
5. FRONT IGNITION spank M COIL PLUGS uu RPMX100 REAR JE 9000 3100A 3 99 4 Install the HI 4E module in the original location using the original hardware Connect the HI 4E plug to the new wire harness you installed in step 1 Your ignition system will now be wired as shown in Figure 2 The two additional Weather Pack plugs are for single fire mode Connections to these plugs are not reguired for standard dual fire operation Refer to page 5 for information about single fire coil hookup 6 Continue to the section below on operation and setup Vacuum advance improves part throttle driveability and fuel economy Do not remove the VOES switch If you are retrofitting an HI 4E to an early H D model fuel economy and driveability will be improved if you install a VOES We recommend you use H D VOES P N 26566 91 Connect it as shown in Figure 2 Advance curves The HI 4E offers a choice of two advance curves which are shown in Figures 5 and 6 The OEM style advance curve is recommended for stock and modified engines Use the race advance curve for high compression engines The advance INSTALLATION ON EARLY MODELS PRIOR TO 1984 1 Figure 1 shows an overview of the ignition system with curves are selected by a DIP switch 2nd position from top of the four section switch at the left side of the unit Use a small screwdriver to slide the switch to the the proper trigger rotor camshaft position sensor and
6. IGNITION MODULE 15 IGNITION COIL 19 VOES CONNECTOR WELL NUTS 2 16 IGNITION COIL amp TERMINAL gt RIVETS 2 OUTER COVER INNER COVER SCREWS 2 INNER COVER GASKET SENSOR PLATE SCREWS amp WASHERS 2 EACH CAMSHAFT POSITION SENSOR ROTOR SCREW amp STAR ASHER IGNITION MODULE CONNECTOR USED ON 1990 AND LATER MODELS ONLY IGNITION MODULE CONNECTOR STYLES 7 PIN D 8 PIN DEUTSCH 0000 2 Refer to Figure 1 for an overview of the ignition system INSTALLATION ON 1984 1990 MODELS The O E ignition module is usually located under the WITHOUT IGNITION PLUG seat under a side cover or on the frame below the han it 1 These models did not have a plug at the ignition mod die bars Unplug the O E module and remove the two ule To install the HI 4E model 8 3100 you will require mounting bolts H D Ignition module adapter wiring harness kit P N 32408 90 This part is not included with the HI 4E and can be purchased from your local dealer Follow the supplied instructions to upgrade your wire harness for plug in ignition Turn ignition switch off and disconnect battery ground cable before starting the installation Refer to Figure 1 for an overview of the ignition system 3 Verify that your HI 4E module has the correct mating plug either a 7 pin D or 8 pin Deutsch style 4 Install the HI 4E module in the original location using the original hardware Connect the HI 4E plu
7. ING DIAL BACK TIMING LIGHT NOTE Applicable to single fire mode only Most dial back timing lights will not work correctly in dual fire mode Determine the advance you want at 2 500 RPM Use a dial back 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 purple white wire while setting the timing with this procedure Set the HI 4E advance slope switch to 9 for maximum advance Run the engine at 2 500 RPM Rotate camshaft position sensor 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 Some dial back timing lights are not compatible with odd firing H D V twin engines Most Sears units are OK Snap On units may not function correctly TROUBLESHOOTING Did the engine run properly before installation of the HI 4E If not remove the HI 4E reinstall the O E ignition or another known good unit and then find and correct the original prob lem Did the HI 4E 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
8. INSTALLATION INSTRUCTIONS for HI 4E PERFORMANCE MOTORCYCLE IGNITION Part Numbers 8 3100 and 8 3101 f ireBall CAUTION READ INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION INTRODUCTION The HI 4E ignition system is intended for use with Harley Davidson motorcycles Model 8 3100 is for 1991 1994 H D applications with 7 pin D style plug and Model 8 3101 is for 1995 and later H DY applications with the new 8 pin Deutsch plug The HI 4E mounts in place of the OE original equipment module and offers easy plug in installation without requiring removal of the timing cover Both models feature the proven advance curves of Crane s original HI 4 Model 8 3100 can also be used with most 1970 90 H D applications however instal lation of additional H D parts is required Use the Applications Index to find the appropriate section for your motorcycle The HI 4E features e Switch selectable multi spark mode Crane s exclusive FIRE Fast Inductive Restrike generates up to nine sparks at idle and three sparks up to 6 000 RPM Reduces lean surge and plug fouling Switch selectable single or dual fire Initially the unit can be installed using the OE dual fire coil With the purchase of a single fire coil such as the Crane 8 3001 the unit con verts to single fire for smoother operation and increased power e Digitally set rev limiter adjustable from 500 to 9 900 RPM in 100 RPM increments via two rotary switches Sequ
9. are for single fire mode Connections to these plugs are not required for standard dual fire operation Refer to page 5 for information about single fire coil hookup HI 4E SETUP AND OPERATION 1 VOES switch Most 1980 and later H D models have a VOES switch which is used to increase the spark advance under high vacuum cruise conditions 3 99 desired position Each advance curve is adjustable over a limited range via the advance slope switch This is a rotary switch that can be set with a small screwdriver Setting the advance slope to zero results in the mini mum lower curve Setting the switch to 9 results in the maximum upper advance curve Intermediate setting result in an advance curve in between the minimum and maximum values with higher switch settings mov ing the curve closer to the maximum values If you use low octane gasoline minimum advance will reduce spark knock Maximum advance will give higher perfor mance but may require the use of high octane gaso line We suggest that you start with an advance slope setting of 5 Then use the highest possible setting that does not cause audible spark knock RPM limiter Two rotary switches are used to digitally set the rev limit from 500 to 9 900 RPM in 100 RPM increments Settings are X100 engine RPM i e 59 5 900 RPM Select a safe rev limit that is less than the red line for your engine Most H D engines with OE valvetrain parts should not be revved over 5
10. ence type rev limiter equalizes cylinder firing at the rev limit and reduces popping and banging Choice of two advance curve families performance advance curve for stock and modified engines and race curve for high compression engines Both curves support the use of the VOES switch for vacuum advance The advance slope of either curve can be adjusted in ten steps via a rotary switch to allow fine tuning the curves to meet particular applications Rear cylinder timing offset digitally set from 5 to 4 degrees via a rotary switch works in both dual and single fire modes Optimizing rear cylinder timing can increase performance when dyno tuning e Choice of start modes electric start with 2 revolution fir ing delay and kick start with immediate firing e Timing LED Indicates TDC top dead center and also serves as a diagnostic aid RA ams The Leader in Performance Technology APPLICATIONS INDEX Late Model With 7 Or 8 Pin Plug Page 1 1991 and later H D models with D style or Deutsch plug at original equipment ignition module 1984 1990 Models Without Ignition Plug Page 2 Early Models Prior To 1984 Page 4 includes early electronic ignition and 1970 and later points equipped models COIL AND SPARK PLUG CABLE CONSIDERATIONS Coils used with the HI 4E must have at least 2 ohms primary resistance Coils with 4 ohms
11. g to the wire harness Your ignition system will now be wired as SHOW hh PIQUE 2 FL series Big Twin models prior to 1985 will require changing the timing rotor refer to Figure 1 You must install H D P N 32402 83 After the HI 4E installation is complete you must reset the ignition timing Refer to your service manual or the information on page 5 5 The two additional Weather Pack plugs are not required for standard dual fire operation The rear coil connec tion is for single fire mode only refer to page 5 6 The tach will fluctuate at the rev limit if the O E tach hookup to Coil is used as shown in Figure 2 For accu rate tach indication at the rev limit connect the tach to the brown wire from the HI 4E as shown in Figure 3 3 The O E ignition module is usually located under the seat under a side cover or on the frame below the han dle bars Remove the O E module and remove the two mounting bolts 7 For initial setup and operation proceed to page 4 3 99 2 9000 3100A FIGURE 2 H D DUAL FIRE IGNITION HOOKUP TRIGGER ROTOR lt E 32402 83 32400 80A BLACK WHITE RED AND GREEN Y VOES BLACK BLACK GROUND TIMING LED 77 A O NIT JON JA HI IG all n F PURPLE WHITE 7 OR 8 PIN PLUG WHITE 12V WEATHER PACK PLUGS USED ONLY FOR SINGLE FIRE HOOKUP a m NE IGNITION 12 VOLT WHITE BLACK a O BATTERY GROUND 12V TACHOMETER MN
12. onnector with the white wire to the rear COIL terminal and the Weather Pack connector with the brown wire to the tach Mating Weather Pack connec tors with an attached length of color coded wire are supplied with the HI 4E You must break the original connection from the tach to the COIL terminal The H D OE tach wire is usually pink On many late models this wire separates from the COIL connection at a main wire harness plug near the ignition mod ule not the 7 or 8 pin plug Refer to your service manual for details TIMING PROCEDURE For most 1984 and later models HI 4E installation does not require resetting the ignition timing For earlier models where a new trigger rotor or camshaft position sensor is installed you must reset the timing The TDC and advance timing marks are located on the fly wheel and can be observed via an inspection hole refer to the shop manual for details Refer to Figure 7 for typical timing marks Early Style includes most 1980 and earlier models Late Style includes most 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 7 and find the diagram with a match ing 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 O E igni
13. tion module Do not use this mark for setting the timing with the HI 4E In most cases an additional mark will remain at 35 BTDC see Figure 7 Use this mark to set the timing with a timing light as described below INITIAL STATIC TIMING PROCEDURE If the engine will not start or runs very rough you can use the following static timing procedure Remove spark plugs and turn engine until TDC mark appears in observation hole Ground spark plugs with an alligator clip so you will not shock yourself Turn on ignition Loosen the standoffs holding camshaft posi tion sensor and rotate it clockwise until timing LED goes out The point at which LED goes off is TDC Timing is now set approximately at TDC which is correct for cranking conditions Turn off ignition and reinstall spark plugs 3 99 ADVANCE TIMING PROCEDURE USING STANDARD TIMING LIGHT This timing procedure requires that a VOES switch be con nected to the HI 4E For racing applications without a VOES switch you must ground the VOES input purple white wire while setting the timing Connect a timing light to the front cylinder Set the HI 4E advance slope switch to 5 midrange Run the engine at 2 400 to 2 500 RPM Rotate camshaft position sensor until advance timing mark is centered in the observation hole Tighten the standoffs and verify that timing has not shifted Timing will now correspond to the curves in Figures 5 or 6 SETTING PRECISE ADVANCE TIMING FOR RACING US
14. volt age trigger pulse In this case install Crane tach adapter P N 8 2050 Note that the tach will read correctly at the rev limit only if it is con nected to the brown wire from the HI 4E Damage to the HI 4 circuitry may have occurred if 12 volts was applied to the brown tach wire at any time 3 99 TOTAL ADVANCE CRANK DEGREES TOTAL ADVANCE CRANK DEGREES FRONT CYLINDER TDC MARK Lal i ES E ital FRONT CYLINDER TDC MARK FRONT CYLINDER TDC MARK FIGURE 5 GEM ADVANCE CURVES kid ADSL ON WAL llo MA A ALOA AC a MIM ADA MH ICH VAD MA ACH LE 1000 2000 3000 4000 5000 8000 7000 8000 9000 ENGINE RPM FIGURE 6 RACE ADVANCE CURVES MIM ADWARE E MAX ADWANCE d HIGH VACUUM DES GROUNDED JAA HA SENI SUON SOI FOOD SUO SULKI ENGINE RPM FIGURE 7 TOP DEAD CENTER TDC AND ADVANCE MARKS FOR VARIOUS MODELS P N FRONT CYLINDER ADVANCE MARK FRONT CYLINDER ADVANCE MARK 1996 AND LATER MODELS 1995 AND LATER EXPORT FRONT CYLINDER 20 MARK DO NOT USE FRONT CYLINDER 35 MARK 8 9000 3100A
15. wiring harness On 1980 to 1983 models you must install a wire harness kit with mating ignition plug and a new trigger rotor Models prior to 1980 will also reguire a new camshaft position sensor 2 All applications will require H D Ignition module adapter wiring harness kit P N 32408 90 This part is not included with the HI 4E and can be purchased from your local dealer Follow the supplied instructions to upgrade your wire harness for plug in ignition Turn igni tion switch off and disconnect battery ground cable before starting the installation 2 All applications will require H D P N 32402 83 trigger rotor After the HI 4E installation is complete you must reset the ignition timing Refer to your service manual or the information on page 5 3 All applications prior to 1980 will require H D P N 32400 80A camshaft position sensor also called the ignition sensor plate 4 The O E ignition module on 1978 and later models is usually located under the seat under a side cover or on the frame below the handle bars Remove the O E module and remove the two mounting bolts 5 Install the HI 4E module in the original location using the original hardware For early points equipped mod els prior to 1978 you may have to fabricate a mounting bracket Connect the HI 4E plug to the new wire har ness you installed in step 1 Your ignition system will now be wired as shown in Figure 2 6 The two additional Weather Pack plugs
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