Service manual

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Daytona Twin Tec LLC, 933 Beville Road, Suite 101-H, S. Daytona, FL 32119 TC88A-IH

(386) 304-0700 www.daytona-twintec.com

9/2011

Page 1

Twin Tec

Installation Instructions for

TC88A-IH Ignition

CAUTION: CAREFULLY READ INSTRUCTIONS BEFORE PROCEEDING.

NOT LEGAL FOR USE OR SALE ON POLLUTION CONTROLLED VEHICLES.

OVERVIEW

Carbureted American IronHorse



Motorcycles

use a non-adjustable ignition system manufactured in

England by Gill. Twin Tec now offers the TC88A-IH

version of our proven TC88A ignition that is compatible

with 2004-2007 American IronHorse



models. The

TC88A-IH version has special firmware that provides

the tach signal required by the IronHorse



instrument

module and proper dwell control for the original

equipment (OE) ignition coils. You cannot use a

standard TC88A unit. Installation involves cutting off

the OE 18 terminal AMP connector used with the Gill

module and replacing it with a 12 terminal Deustch

connector supplied with the TC88A-IH kit. On 2005 and

later models, some minor rewiring of the MAP sensor

and engine temperature sensor ground connections is

required.

The TC88A-IH offers adjustable advance and

adjustable RPM limit settings in 100 RPM increments.

The TC88A-IH also features built-in data logging that

stores data for the last 30 minutes of engine operation

including RPM, manifold pressure, ignition advance,

and battery voltage. Engine builders will find the data

logging feature highly useful for tuning, diagnosing

problems, and reducing unjustified warranty claims.

Figure 1 – TC88A-IH Ignition Module

Twin Tec PC link software along with an optional

USB interface cable (P/N USB-INTF) and power

adapter (TC88A-ADAPT) allow the use of a laptop PC

to program a custom advance curve for precise dyno

tuning and download data logged by the unit.

INSTALLATION OVERVIEW

Before proceeding you must have access to a

proper Deutsch crimping tool and experience with the

Deutsch connectors. For more information, you can

refer to the Deutsch connector section in any recent

Harley-Davidson



electrical diagnostic manual. Ladd

Industries (www.laddinc.com

) sells a low cost crimping

tool, Deutsch P/N DTT-16-00. On 2005 and later

models, some wires will have to be extended. Solder

all wire joints and cover with shrink tubing.

PRE-INSTALLATION CHECK FOR

CORRECT CRANKSHAFT POSITION

SENSOR AIR GAP

Customers have frequently encountered

problems with the crankshaft position (CKP) sensor air

gap. The S&S Cycle



engine used on American

IronHorse



motorcycles does not have the same

tolerances for the CKP sensor mounting as a standard

H-D



Twin-Cam. The same applies to the Gill CKP

sensor.

You must check the CKP sensor air gap. The

sensor output voltage is proportional to RPM and drops

off sharply as the air gap increases. The air gap must

be .030-.045" for proper system operation. If the air

gap is greater than .045", the ignition module will not

trigger correctly at low cranking RPM.

Remove the CKP sensor. Use a dial caliper to

measure the clearance between the sensor mounting

surface on the engine crankcase and the top of the

flywheel teeth. Then measure the length of the sensor

from the sensor flange to the tip. The air gap is the

difference between these two measurements. If the air

gap exceeds .045”, it must be corrected by machining

or filing some material from the bottom of the sensor

flange (to cause the sensor tip to protrude further into

the crankcase).

Summary of content (12 pages)

PAGE 1
Twin Tec Installation Instructions for TC88A-IH Ignition CAUTION: CAREFULLY READ INSTRUCTIONS BEFORE PROCEEDING. NOT LEGAL FOR USE OR SALE ON POLLUTION CONTROLLED VEHICLES. OVERVIEW Carbureted American IronHorse Motorcycles use a non-adjustable ignition system manufactured in England by Gill. Twin Tec now offers the TC88A-IH version of our proven TC88A ignition that is compatible with 2004-2007 American IronHorse models.
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INSTALLATION ON 2004 MODELS 1. Turn off the ignition switch and disconnect the battery ground cable before proceeding. 2. Refer to Figures 2 and 3 for wiring details. 3. Remove the Gill Module. 1. Cut off the OE 18 terminal AMP connector used with the Gill module. Refer to the terminal list. Crimp new Deutsch terminals on the wires, and install into the 12 terminal Deutsch connector required by the TC88A-IH module. Any additional unused black ground wires can be removed or taped up. 4.
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Terminal List for American IronHorse Ignition Conversion TC88A Deutsch Connector OE AMP Connector Signal Wire Color Code 1 2 +12V Power W/R 2 15 Tach W/V 3 4 Sensor Power GN 4 N/A Sensor Ground – 2005 and later models only 5 1 Module Ground BK 6 8 Coil Front (#1) BN/GY 7 14 Coil Rear (#2) GY/R 8 6 CKP Sensor Signal R/BK 9 5 CKP Sensor Return BK/GN or BK/GY 10 N/A VSS Input – not used 11 17 MAP Input 12 N/A J1850 Serial Data – not used Y/R Wire Color Codes C
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MAP SENSOR Figure 2 – 2004 American IronHorse OE Ignition Wiring Diagram CRANKSHAFT POSITION (CKP) SENSOR GILL IGNITION MODULE CONNECTOR PIN NUMBERS (WIRE ENTRY SIDE VIEW) 18 17 16 15 12 6 B 5 4 14 13 9 3 8 2 7 1 A 1 2 17 4 1 2 8 14 6 5 15 C 11 10 MAP INPUT Y/R SENSOR PWR GN CKP SIGNAL R/BK SENSOR GND COIL REAR GY/R +12V POWER W/R INSTRUMENT CLUSTER TACH W/V GROUND BK COIL FRONT BN/GY CKP RETURN BK/G GILL IGNITION COILS TO FRONT SPARK PLUG TO REAR SPARK PLUG TO +12V Daytona
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Figure 3 – 2004 American IronHorse TC88A-IH Ignition Wiring Diagram 901 901 901 78 78 901 78 MAP SENSOR 23 456 23 456 23 456 456 23 78 INITIAL ADVANCE X1000 X100 MODE TIMING SLOPE RPM LIMIT ADJUST CRANKSHAFT POSITION (CKP) SENSOR TC88A-IH IGNITION MODULE B A 1 2 11 3 5 1 6 7 8 9 2 C MAP INPUT Y/R SENSOR PWR GN CKP SIGNAL R/BK CKP RETURN BK/GY COIL REAR GY/R +12V POWER W/R INSTRUMENT CLUSTER TACH W/V GROUND BK COIL FRONT BN/GY SENSOR GND GILL IGNITION COILS TO FRONT SPAR
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GILL IGNITION MODULE CRANKSHAFT POSITION (CKP) SENSOR ENGINE TEMP (ET) SENSOR MAP SENSOR Figure 4 – 2005 and Later American IronHorse OE Ignition Wiring Diagram 17 16 15 12 6 B 5 4 14 13 9 3 8 2 7 1 A 17 4 1 2 8 14 6 5 15 18 C 11 10 ET SIGNAL PK/Y 18 MAP INPUT Y/R SENSOR PWR GN ET RETURN BK/GN CONNECTOR PIN NUMBERS (WIRE ENTRY SIDE VIEW) 1 2 CKP SIGNAL R/BK SENSOR GND COIL REAR GY/R +12V POWER W/R INSTRUMENT CLUSTER TACH W/V GROUND BK COIL FRONT BN/GY CKP RETURN BK/GY GILL
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Figure 5 – 2005 and Later American IronHorse TC88A-IH Ignition Wiring Diagram 78 78 INITIAL ADVANCE X1000 X100 MODE TIMING SLOPE RPM LIMIT ADJUST TC88A-IH IGNITION MODULE A MAP INPUT Y/R SENSOR PWR GN B ET RETURN BK/GN B 11 3 5 1 6 7 8 4 2 9 C ET SIGNAL PK/Y A NOTE: CUT AND TAPE UP ET SENSOR LEADS. ISOLATE CKP RETURN AND MAP SENSOR GROUND. TEST WITH DVM TO VERIFY ISOLATION (NO CONTINUITY) BETWEEN TERMINALS 4 AND 9.
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RECOMMENDED TIMING SETTINGS The American IronHorse engine utilizes a nonadjustable crankshaft position sensor. Thus no mechanical means exist for adjusting the timing. The TC88A-IH module overcomes this limitation. The initial timing switch allows you to shift the entire advance table up or down. Lower switch settings decrease (retard) the initial timing and higher switch settings increase (advance) the initial timing in one-degree steps.
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work in demo mode without a TC88A-IH module attached. If you program a custom advance curve, make sure that you leave the tach output enabled under module parameters (refer to PC Link TC88 instructions for details), otherwise the tach will not function. DIAGNOSTICS AND DATA LOGGING The TC88A-IH features built-in data logging that stores data for the last 30 minutes of engine operation including RPM, vehicle speed, manifold pressure, ignition advance, and battery voltage.
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Figure 6 - Graph Representing Advance Slope Setting 0 (Least Aggressive) 45 16 IN-HG 18 IN-HG DECEL 40 20-INHG 22 IN-HG 24 IN-HG 26 IN-HG 28 IN-HG 30 IN-HG 35 ADVANCE (DEG) 30 25 WOT 20 15 10 5 0 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 ENGINERPM Figure 7 - Graph Representing Advance Slope Setting 5 (Nominal) 45 16 IN-HG 18 IN-HG DECEL 40 20-IN HG 22 IN-HG 24 IN-HG 26 IN-HG 35 28 IN-HG 30 IN-HG ADVANCE (DEG) 30 WOT 25 20 15 10 5 0 0 500 1000 1500 2000
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Figure 8 - Graph Representing Advance Slope Setting 9 (Most Aggressive) 45 16 IN-HG 18 IN-HG 20-IN HG 22 IN-HG 24 IN-HG 26 IN-HG 28 IN-HG 30 IN-HG DECEL 40 35 WOT ADVANCE (DEG) 30 25 20 15 10 5 0 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 ENGINE RPM Daytona Twin Tec LLC, 933 Beville Road, Suite 101-H, S. Daytona, FL 32119 (386) 304-0700 www.daytona-twintec.
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Troubleshooting Flowchart STARTING POINT REPLACE TC88A WITH ANOTHER KNOWN GOOD MODULE. DOES ENGINE START? YES NO REPAIR UNDERLYING PROBLEM BEFORE REINSTALLING TC88A. REFER TO MOTORCYCLE SERVICE MANUAL REINSTALL TC88A DOES ENGINE START? NO YES USE TC88A LOG SOFTWARE TO CHECK FOR DIAGNOSTIC CODES. ARE ANY CODES SET? REPLACE TC88A NO YES REFER TO TC88A DIAGNOSTICS SECTION. FIX APPLICABLE PROBLEM. DOES ENGINE STOP OR DROP CYLINDER AFTER SEVERAL MINUTES OF RUNNING? NO YES REPLACE COILS.