CAUTION: CAREFULLY READ INSTRUCTIONS BEFORE . - V-Twin Mfg
Twin TecInstallation Instructionsfor Ignition Model 1005CAUTION: CAREFULLY READ INSTRUCTIONS BEFORE PROCEEDING.NOT LEGAL FOR USE OR SALE ON POLLUTION CONTROLLED VEHICLES.OVERVIEWTwin Tec ignition Model 1005 is intended for usewith Harley-Davidson Evolution type motorcycleengines. The Model 1005 replaces the originalequipment (OE) electronic ignition system on 1978-99models. The unit mounts in the gear case cover anduses the standard H-D timing rotor. It can also beused on earlier models with breaker points andmechanical advance. Please note that the 1005S-EX isrecommended for 1998 and later Sportster models asit mates directly with the OE wiring harness.The Model 1005 offers adjustable advance,adjustable RPM limit settings in 100 RPM increments,and switch selectable single or dual fire modes. Singlefire mode improves starting, reduces the occurrence ofbackfiring at low RPM, and improves power at highRPM. A red status LED flashes when the enginereaches top dead center (TDC) and allows easy statictiming. The status LED also provides diagnosticinformation. A green VOES LED illuminates when theVOES (vacuum switch) input is active.A special feature allows use of the tachometerwire for a PC link to a laptop computer when theengine is not running. Individual units can beprogrammed with a custom advance curve and otherengine parameters such as rear cylinder timing offset.The use of the tachometer wire for the PC linkeliminates the need to remove the outer cover plate.All Model 1005 units log engine operating datathat may be downloaded and viewed with ourOperating Statistics software. Model 1005 unitsmanufactured starting January, 2006 include a build-intemperature sensor and logging of temperature data.AVOIDING HEAT RELATEDFAILURESHeat kills electronics. The Model 1005 useselectronic devices rated for operation at 105 deg C(221 deg F), the highest rating available. The unit cantolerate somewhat higher temperatures, but exposureto temperatures above 125 deg C (257 deg F) willgreatly reduce life expectancy. We sometimes seeproblematic applications where several module failureshave occurred. The failure mode is a classic thermalintermittent where the module stops firing one cylinderwhen it gets hot. We have found that these problematicapplications share one or more of the followingcharacteristics: VOES switch removed or non-functional. All streetdriven engines require vacuum advance. Withoutvacuum advance at idle and part throttle,thermodynamic efficiency is reduced and enginetemperatures increase significantly. Improper carburetor jetting resulting in lean air/fuelratio (AFR). A lean AFR will cause the engine torun very hot. All performance engine modificationsnecessitate carburetor rejetting. Carburetors arenever correctly jetted out-of-the-box. The onlypractical means of correctly jetting a carburetor isto test the motorcycle on a chassis dyno equippedwith an exhaust gas sniffer or to use our WEGOsystem. Lack of an oil cooler on a 95 CID or larger engine. Exhaust pipe without heat shield in close proximityto the nose cone.If any of the above applies to your application,the Model 1005 may be exposed to excessivetemperatures resulting in reduced life expectancy. Usean infrared thermometer to check the moduletemperature. Can you also our Operating Statisticssoftware to monitor temperature levels. If excessivetemperatures are encountered and cannot beremedied, you should consider using an externalmodule such as our Model 1006 or 1007.INCLUDED AND ADDITIONALREQUIRED PARTSAll units include a parts bag with crimp terminalsfor coil and VOES hookup and a Packard WeatherPack connector set intended for installation on thetachometer wire to provide an access point for the PClink.FL series Big-Twin models manufactured priorto 1985, FX series Big-Twin and XL Series Sportster models manufactured prior to 1984, all Sportster Daytona Twin Tec LLC, 933 Beville Road, Suite 101-H, S. Daytona, FL 32119(386) 304-0700 www.daytona-twintec.comPage 1Model 100511/2012
1200S models, and all models with original equipmentbreaker points will require H-D timing rotor P/N 3240283 or an equivalent aftermarket part.Figure 2 - Installing Unit (Note Orientation)INSTALLATION1. Turn off the ignition switch and disconnect thebattery ground cable before proceeding.2. Refer to Figure 1. Remove gear case cover plateand mounting hardware. You may have to drill outtwo rivets that hold the cover (reassemble withsupplied self-threading screws). Remove thesensor plate or breaker points. Make sure that thecorrect H-D P/N 32402-83 timing rotor is installed.Figure 1 - Feeding Harness Thru Exit HoleFigure 3A - Finished Big-Twin Installation3. You can completely remove the OE ignitionharness and external module (1980 and latermodels) if desired. However, you must disconnectall OE wires from the coil except the white/blackwire from the engine stop/run switch.4. Install the Model 1005 unit. Wrap one turn ofelectrical tape around the end of the protectivewire harness sleeve. This will compress the sleeveand allow you to easily feed it through the cableexit hole in the gear case cover. The tape will alsokeep the sleeve end from fraying. You will have toenlarge the hole with a drill on early models andsome Sportsters .5. Rotate the unit and then place it into position asshown in Figure 2. Be careful to avoid damage tothe black plastic Hall Effect sensors on the bottomof the unit.6. Route the wiring harness along the side of the unitand install the mounting standoffs as shown inFigure 3A for Big Twin or 3B for Sportster models.Do not fully tighten the standoffs or install the outercover plate until after the static timing procedure.7. Route the wire harness along the frame tubing tothe ignition coil. Make sure that the harness isclear of hot exhaust areas and cannot chafeagainst sharp edges. Secure the harness withnylon cable ties.Daytona Twin Tec LLC, 933 Beville Road, Suite 101-H, S. Daytona, FL 32119(386) 304-0700 www.daytona-twintec.comPage 2Model 100511/2012
Figure 3B - Finished Sportster InstallationCAUTION: Single fire only. Failure toisolate the tach wire from the coil willcause damage to the Twin Tec modulethat is not covered under warranty.the pink coil wire. Trace the wire going all the wayback to the tach to avoid an inadvertent coilconnection.11. Reconnect the battery ground cable. Complete thesetup and timing procedures given on pages 3-7.12. Reinstall the cover plate using two supplied 10-24x 1/4" socket head screws and lock washers inplace of the original rivets. You will have to tap therivet holes on the inner plate (do this with the plateremoved from the bike to avoid damaging theignition). You can use the supplied 10-24 x 3/8"self threading screw as a tap.8. Refer to the appropriate wiring diagram. Use thedual fire hookup shown in Figure 4 if you have anOE coil or other coil with two primary terminals.Use the single fire hookup in Figure 5 if you areinstalling an aftermarket coil with three primaryterminals. Use appropriate crimp terminals for coiland VOES hookup. With the exception of thetachometer and rear coil section (single fire only),standard H-D wire color codes are used. Tape upany unused wires.CAUTION: Engine damage fromexcessive timing advance may result ifthe purple/white VOES wire isinadvertently shorted to ground.NOTE: The unit is grounded by meansof the gear case housing. The mountingsurface must not be anodized orpainted.OPERATING MODESA single 10 position rotary switch is used toselect the operating mode. Switch settings are asfollows:0 Street advance curves, dual fire, multi-spark disabled1 Street advance curves, dual fire, multi-spark enabled2 Street advance curves, single fire, multi-spark disabled3 Street advance curves, single fire, multi-spark enabled4 Race advance curves, dual fire, multi-spark disabled9. Install the supplied Weather Pack connector set onthe brown tachometer wire as shown. If atachometer is not used, seal the end of the matingplug with silicone RTV and use it as a protectivecover. Use a proper Weather Pack crimping tool orsolder the terminals. Pioneer-Standard(www.packard.pios.com) sells Packard crimpingtool P/N 12014254. Snap-on sells a low cost tool,P/N PWC30.10. Single Fire Tach Hookup. If your motorcycle hada tach before installation of the Twin Tec module,the tach was connected to the pink coil wire. Whenyou connect the tach direct to the Twin Tec moduleas shown in Figure 5 for a single fire application,you must make sure that it is not still connected to5 Race advance curves, dual fire, multi-spark enabled6 Race advance curves, single fire, multi-spark disabled7 Race advance curves, single fire, multi-spark enabled8 Boot load mode (factory use only - see text)9 Race advance curves, single fire, kick start (see text)The engine will not run if the mode switch settingdoes not match the wiring hookup (i.e. you cannotselect single fire mode with a dual fire coil hookup).Advance curve families are shown in Figures 6and 7. Use the street advance curves (mode switchsettings 0-3) for stock or mildly modified engines. UseDaytona Twin Tec LLC, 933 Beville Road, Suite 101-H, S. Daytona, FL 32119(386) 304-0700 www.daytona-twintec.comPage 3Model 100511/2012
the race advance curves (mode switch settings 4-7) forhigh compression engines.We recommend that you enable multi-spark.When multi-spark is enabled, a continuous series ofsparks is fired from the advanced timing point untilTDC. Most air-cooled engines require relatively coldspark plugs to prevent detonation under high load.Multi-spark reduces the consequent tendency for plugfouling at idle.Switch setting 8 is a factory reserved settingused for a special "boot load" mode that allows loadingan entirely new program into the processor FLASHmemory.Switch setting 9 is available on revision 8.3 andlater units (revision is labeled on back of unit) andselects race advance curves, single fire, and kick startmode. Multi-spark is disabled.Figure 4 - Dual Fire Wiring DiagramENGINESTOP/RUNSWITCHWHITE/BLACKTO 12VDUAL FIRE COILOPTIONAL VOES(VACUUM SWITCH)TO FRONTSPARKPLUGWHITE/BLACKTO REARSPARKPLUGPURPLE/WHITEPINKTAPE UP WIRE IFVOES NOT USEDOPTIONAL TACHADJUSTMODE ADVANCE RPM LIMITSELECT SLOPE X1000 X10090190178901BLUE WIRE USEDFOR SINGLE FIREONLY - TAPE AL CABLE CONNECTED TOBROWN TACH WIRE DURING PC LINKTwinTecInternal IgnitionModel 1005BROWNFEMALE TERMINALMALE TERMINALWEATHER PACK CONNECTORSTO PCSERIALPORTMODE SETTINGS FOR DUAL FIRE0 STREET ADVANCE CURVES, MULTI-SPARK DISABLED1 STREET ADVANCE CURVES, MULTI-SPARK ENABLED4 RACE ADVANCE CURVES, MULTI-SPARK DISABLED5 RACE ADVANCE CURVES, MULTI-SPARK ENABLEDDaytona Twin Tec LLC, 933 Beville Road, Suite 101-H, S. Daytona, FL 32119(386) 304-0700 www.daytona-twintec.comPage 4Model 100511/2012
Figure 5 - Single Fire Wiring DiagramENGINESTOP/RUNSWITCHTO 12VSINGLE FIRE COILWHITE/BLACKOPTIONAL VOES(VACUUM SWITCH)TO FRONTSPARKPLUG PINKWHITE/BLACKBLUETO REARSPARKPLUGPURPLE/WHITETAPE UP WIRE IFVOES NOT USEDOPTIONAL TACHADJUSTMODE ADVANCE RPM LIMITSELECT SLOPE X1000 WEATHER PACK CONNECTORSFEMALEMALE TERMINALVOESTwinTecRPMInternal IgnitionModel 1005BROWNMODE SETTINGS FOR SINGLE FIRE2 STREET ADVANCE CURVES, MULTI-SPARK DISABLED3 STREET ADVANCE CURVES, MULTI-SPARK ENABLED6 RACE ADVANCE CURVES, MULTI-SPARK DISABLED7 RACE ADVANCE CURVES, MULTI-SPARK ENABLED9 RACE ADVANCE CURVES, KICK STARTRECOMMENDED TIMING SETTINGSStreet and race advance curve families areshown in Figures 6 and 7. Each family has minimumand maximum curves. The advance slope switchallows you to run an advance curve in between theseminimum and maximum curves. Advance slope switchsetting zero corresponds to the minimum advancecurve. Switch setting 9 corresponds to the maximumadvance curve. Higher switch settings result in a moreaggressive curve.TO PCSERIALPORTOPTIONAL CABLE CONNECTED TOBROWN TACH WIRE DURING PC LINKTuning a particular engine setup always requiressome trial and error experimentation, but maximumpower is usually obtained by using the highest advancesetting possible without audible spark knock. Somerecommended starting points are given below:For stock engines run on normal pump gas (8789 octane), use the street advance curves andadvance slope setting 5.For stock or mildly modified engines run on 92or higher octane gas, use the street advance curvesand advance slope setting 7.Daytona Twin Tec LLC, 933 Beville Road, Suite 101-H, S. Daytona, FL 32119(386) 304-0700 www.daytona-twintec.comPage 5Model 100511/2012
For high compression engines, use the raceadvance curves and advance slope setting 2.You can adjust the initial timing by rotating theTwin Tec module relative to the gear housing(clockwise rotation increases initial timing).If you experience spark knock only at low RPM,you can try reducing the initial timing while maintainingan aggressive advance slope for maximum power athigh RPM by increasing the advance slope switchsetting. If spark knock is a problem at high RPM,decrease the advance slope switch setting.Once you have determined the best switchsettings, you can further optimize the timing at aparticular RPM by programming a custom advancecurve with our PC Link software and optional cable.Note that the wide-open throttle (WOT) curvesare active unless the VOES input is grounded. Duringidle and cruise, the VOES input is grounded (greenVOES LED illuminated) and the low manifold pressure(MAP) curves are active.TUNING TIP: Lean air/fuel ratio (AFR)increases the tendency for sparkknock. Check AFR and rejet carburetorbefore optimizing ignition timing. Testthe motorcycle on a dyno with anexhaust gas sniffer or use our WEGO.RPM LIMITER SETTINGYou can set the RPM limit from 3,000 to 9,900RPM in 100 RPM increments by means of two rotaryswitches. The RPM limit is X100 switch setting (i.e. 57 5,700 RPM). Inadvertent settings below 3,000 RPMare ignored and result in a 3,000 RPM limit.The Model 1005 uses a newly developed RPMlimiting algorithm that has been highly optimized forodd firing V twin engines. When the engine is heldagainst the RPM limit, cylinder firing is always paired.This eliminates a torque couple and results in verysmooth operation compared to random or sequencetype RPM limiters.Set a safe RPM limit that is appropriate for yourengine. Most Evolution engines with OE valvetraincomponents should not be run over 5,700 RPM.STATIC TIMING PROCEDURE1. Timing marks are located on the flywheel and maybe viewed by unscrewing the inspection hole plug.Most engines will have both TDC and advancetiming marks for the front cylinder as shown inFigure 8. If you are not sure, refer to your shopmanual. You can also identify the TDC mark byremoving the spark plugs and rotating thecrankshaft (turn rear wheel in high gear) until thefront piston comes up on TDC.2. For static timing, you must rotate the crankshaft sothat the front piston is at TDC on the compressionstroke. Remove spark plugs and rotate crankshaft.If you place your thumb over the spark plug hole,you will feel pressure as the piston comes up onthe compression stroke. Continue rotating thecrankshaft until the TDC mark is precisely centeredin the inspection hole.3. Ground the spark plug cables to avoid a shockhazard. You can use small jumper wires withalligator clips for this purpose.4. Turn on the ignition switch. The red LED is used asa timing indicator. Note that the LED does notimmediately illuminate when power is firstturned on. Rotate the ignition unit back and forthuntil the red LED illuminates. Then slowly rotatethe unit clockwise until the LED goes out. Note thatthe LED goes out at TDC.5. Tighten the standoffs to secure the unit. Turn offthe ignition switch and reinstall the spark plugs.PRECISE TIMING PROCEDURE1. Use a standard timing light. Note that most dialback type timing lights will not work correctly withdual fire applications. If you have a dial-back timinglight, set the dial-back to zero. Do not enable multispark while setting timing.2. The precise timing procedure is based on using the35 BTDC timing mark and race maximumadvance curve with VOES grounded that reaches35 BTDC around 2,000 RPM (refer to Figure 7).To use this procedure, you must have a VOESswitch connected. If a VOES switch is not used,you must ground the purple/white wire whilesetting the timing.3. Set mode switch to 4 for dual fire or 6 for singlefire. Set advance slope switch to 9. Connect thetiming light pickup to the front cylinder spark plugcable. Loosen standoffs securing the ignition unit.Run the engine at a steady speed just over 2,000RPM. Rotate the ignition to center the 35 BTDCtiming mark in the inspection hole. Tightenstandoffs and verify that the timing has notchanged. When done, change mode and advanceslope switches back to desired values.Daytona Twin Tec LLC, 933 Beville Road, Suite 101-H, S. Daytona, FL 32119(386) 304-0700 www.daytona-twintec.comPage 6Model 100511/2012
Figure 6 - Street Advance Curves4035ADVANCE (DEG)3025201510MAX ADVANCE AT WIDE OPEN THROTTLEMIN ADVANCE AT WIDE OPEN THROTTLEMAX ADVANCE WITH VOES GROUNDEDMIN ADVANCE WITH VOES GROUNDED5001000200030004000500060007000ENGINE RPMFigure 7 - Race Advance Curves4035ADVANCE (DEG)3025201510MAX ADVANCE AT WIDE OPEN THROTTLEMIN ADVANCE AT WIDE OPEN THROTTLEMAX ADVANCE WITH VOES GROUNDEDMIN ADVANCE WITH VOES GROUNDED5001000200030004000500060007000ENGINE RPMDaytona Twin Tec LLC, 933 Beville Road, Suite 101-H, S. Daytona, FL 32119(386) 304-0700 www.daytona-twintec.comPage 7Model 100511/2012
Figure 8 - Front Cylinder Timing MarksEARLY STYLETDC35 BTDCLATE STYLETDC35 BTDC1996 AND LATER (1995 AND LATER EXPORT)TDC20 BTDC (NOT USED)GENERAL RECOMMENDATIONSCoil primary resistance must not be less than 3ohms. Most OE style dual fire and aftermarket singlefire coils meet this requirement. Coils for the new TwinCam 88 engine have low primary resistance and arenot compatible.Due to the short lengths involved on motorcycleapplications, energy losses in spark plug wires areinsignificant. OE carbon core suppression cables willdeteriorate after several years. For a more durablereplacement, we suggest spiral core spark plug cables.CAUTION: Do not use solid copperspark plug cables or non-resistor typespark plugs. The unit may misfire.The Twin Tec module is compatible with allmodern "ground sensing" type tachometers includingH-D OE and Autometer units. The red status LED isinternally connected to the tachometer output. If thered status LED blinks, the tachometer output should befunctional. Some early tachometers require a highvoltage trigger pulse. In this case, you will require acommercially available tachometer adapter.VOES CONSIDERATIONSThe vacuum switch (VOES) provides thevacuum advance required by all street driven engines.Additional advance under low manifold pressureconditions improves idle stability and fuel economy.Most 1980 and later motorcycles are equipped with aOE VOES. Without vacuum advance at idle and part35 BTDCthrottle, thermodynamic efficiency is reduced andengine temperatures increase significantly.The VOES is normally open. At low manifoldpressure (or manifold vacuum greater than about 5inch-Hg), the VOES grounds the purple/white wire andcauses the Twin Tec module to generate additionaltiming advance. The green VOES LED illuminateswhenever the VOES input is active (timing advanced).Refer to the Evo Tech FAQ on our website for moreVOES information.The use of a VOES is required for properoperation of the Twin Tec module. If your motorcycledid not include an OE VOES, you can use H-D VOESP/N 26566-91 for stock or mildly modified engines. Forhigh performance engines, we recommend our P/NVOES-KIT-MC7. This is a complete kit with mountingbracket and has a higher vacuum switching level (6-7inch-Hg) that helps eliminate spark knock under lightload or throttle roll-on.PC LINK CABLE AND SOFTWAREThe new Twin Tec USB Interface (P/N USBINTF) pr
Twin Tec Installation Instructions for Ignition Model 1005 CAUTION: CAREFULLY READ INSTRUCTIONS BEFORE PROCEEDING. NOT LEGAL FOR USE OR SALE ON POLLUTION CONTROLLED VEHICLES. OVERVIEW Twin Tec ignition Model 1005 is intended for use with Harley-Davidson Evolution type motorcycle engines. The Model 1005 replaces the original
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