S&S Cycle IST Ignition System for 1984–99 4 1/8 Bore Big Twin Engines User Manual

Page 8

• .200" Spacers (4)

• .060" Spacers (4)

• .475" O.D. Washers (2)

• .250 I.D. Lockwashers (2)

NOTE: Locking tabs on each connector listed should produce a light “click” sound when properly assembled. S&S® recommends checking each connection

by lightly pulling on each half of the connector to insure that the locking tabs have properly seated.

a. Route the wiring harness along the bike frame to ensure that the Ignition Module Connector (a) (See Picture 11, below) reaches the

Module mounting location.

b. Connect the Ignition Module Connector (a) (See Picture 11) to the Module.

c. Install the module using the stock mounting hardware and the S&S hardware (if necessary) included with the module.

d. Plug the 8-pin black plug from the stock wiring harness into the black 8-socket Motorcycle Main Harness Connector (b) on the S&S

harness. See Picture 11 (if the motorcycle plug has only seven pins see step 7)

e. The portion of the harness that connects to the Head Temperature Sensor, MAP Sensor, and the Knock Sensor should be routed along

with the stock wiring under the gas tank.

f. Use the provided wire ties to secure this portion of the harness to the motorcycle frame or a portion of the existing harness. Do not allow

the harness to touch cylinder or head fins which get very hot.

g. See Picture 11. Connect the Head Temperature Connector (c) Knock Sensor Connector (d) and MAP Sensor (e) to the corresponding

sensors.

NOTE: If the tank is removed or raised, temporarily replace it to insure clearance for the Engine Temperature, MAP, and Knock Sensor portions of the

harness. Reroute any wires that may be damaged by installing the tank.

h. Connect the main harness segment (f) (See Picture 11) to the coil harness (item (e) in Picture 1) and route the harness to the coil. Table 1

shows the wire color codes that should be matched to the ignition coil. Attach each ring terminal to the corresponding terminal on the
coil. Do not allow the terminals to touch each other or any other metal. See Picture 12, next page.

i. Route the main harness segment (g) (See Picture 11) on the S&S harness to the Crank Position Sensor and attach the connector. Avoid

routing this wire segment near coils or spark plug wires.

j. Locate main harness segment (h) (See Picture 11) on the S&S harness so that it may be easily accessed to check for fault codes should

they occur. See Picture 13, next page.

k. Permanently reinstall tank, reconnect battery (positive cable first) and any other portions of the motorcycle that have been removed or

disconnected.

Picture 11

Table 1

Wire Color

Coil Terminal

Designation

Main

Stripe

White

Black

Battery “+”

Yellow

Blue

Rear Cylinder

Blue

Orange

Front Cylinder