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ACCEL IGNITION www.accel-ignition.com

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

Summary of content (8 pages)

PAGE 1
FORM 97140090 INSTALLATION INSTRUCTIONS Ignition Model #35496 CAUTION: CAREFULLY READ INSTRUCTIONS BEFORE PROCEEDING. NOT LEGAL FOR USE OR SALE ON POLLUTION CONTROLLED VECHICLES OVERVIEW ACCEL Ignition Model 35496 is intended for use with Harley-Davidson® Evolution® type motorcycle engines. The Model 35496 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.
PAGE 2
Figure 2 - Installing Unit (Note Orientation) 7. 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. Figure 3A - Finished Big-Twin® Installation 8. 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.
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OPERATING MODES A single 10 position rotary switch is used to select the operating mode.
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Figure 5 - Single Fire Wiring Diagram 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 exhaust gas sniffer. 4 www.accel-ignition.
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RECOMMENDED TIMING SETTINGS STATIC TIMING PROCEDURE 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.
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Figure 7 - Race Advance Curves 40 35 ADVANCE (DEG) 30 25 20 15 10 MAX ADVANCE AT WIDE OPEN THROTTLE MIN ADVANCE AT WIDE OPEN THROTTLE MAX ADVANCE WITH VOES GROUNDED MIN ADVANCE WITH VOES GROUNDED 5 0 0 1000 2000 3000 4000 5000 6000 7000 ENGINE RPM Figure 8 - Front Cylinder Timing Marks 6 www.accel-ignition.
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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 engine have low primary resistance and are not compatible. Due to 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.
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ACCEL IS A TRADEMARK OF ACCEL PERFORMANCE GROUP 10601 MEMPHIS AVE. #12, CLEVELAND, OHIO 44144 216.688.8300 FAX 216.688.8306 8 www.accel-ignition.