NORTON LIGHTWEIGHT TWIN ELECTRONIC IGNITION Installation Instructions

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Filed Under (Norton) by admin on 31-10-2010

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1. All connections must be of the highest quality, use crimped or soldered connections; twisted wires will not give a satisfactory operation. 2. Remove the petrol tank and/or seat to gain access to the ignition coils, condensers and wiring. 3. For safety, disconnect the battery (preferably both terminals). 4. Remove timing cover. 5. Disconnect the two wires (usually black-white & black-yellow) and remove the contact-breaker plate. At the other end, these two wires must be disconnected from the ignition coils & condensers. The condensers are no longer required and can be removed. They should not be connected to the electronic ignition system. 6. Remove auto-advance unit. 7. Disconnect the remaining wires from the ignition coils. These come from the ignition switch supply. The colour of this ignition supply wire may be different on some machines; if so check using a test lamp or meter to find the live wire when the ignition is switched on. 8. Find a suitable place for the ignition module, preferably near to the ignition coils. Secure the ignition module to the frame using one or more large cable ties. An adhesive mounting base is provided; this can be affixed to the underside of the module and the cable tie passed through and around the module and frame. Do not completely wrap the module in foam rubber. 9. Using the black coil link wire, connect the negative (—) terminal of one ignition coil to the positive (+) terminal of the other ignition coil. See figs. 1/2 on page 7. • BLACK COIL LINK WIRE • RED EARTHING WIRE • CRIMP CONNECTORS & INSULATORS • LARGE & SMALL CABLE TIES • CABLE TIE ADHESIVE MOUNTING BASE 3 10. Take the black wire from the ignition module, cut to length and fit an insulator and female spade connector to the end. Connect to the negative (—) terminal on ignition coil #2. See figs. 1/2 on page 7. 11. Take the red wire from the ignition module, cut to length and fit an insulator and female spade connector to the end. Connect to the positive (+) terminal on ignition coil #1. See figs. 1/2 on page 7. 12. For NEGATIVE EARTH electrics go to step 15. 13. For POSITIVE EARTH electrics (standard): Take the white wire from the ignition module, cut to length and fit an insulator and male spade connector to the end. Connect to one of the negative ignition feed wires previously removed in step 7. The other wire (if fitted) is spare and should be covered with insulation to prevent shorting to the frame etc. 14. Take the red earthing wire, fit an insulator and female spade connector on one end and connect to the positive (+) terminal on ignition coil #1. Cut to length and fit a ring terminal on the other end and connect to a good earth point on the frame, ideally the battery positive (+) terminal. See fig.1 GOTO STEP 17.

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4-STROKE TRIUMPH SINGLE CYLINDER MOTORCYCLES ELECTRONIC IGNITION SYSTEM INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 27-10-2010

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1. Remove the petrol tank (and seat if necessary) to gain access to the ignition coil, condensor and wiring. 2. For safety, disconnect the battery, if fitted (preferably both terminals). 3. Remove the spark plug. 4. Remove the alternator rotor cover (if fitted). 5. Loosen the auto-advance centre bolt. Rotate the engine to the correct full advance timing position for your machine (see table on page 6), using one of these methods: • Models from 1967 on: use the marks provided for strobe timing on the rotor & chaincase (inside the rotor cover). Unless these marks are known to be accurate it is recommended that they are checked for correct alignment. These marks should line up at the full advance position, check using one of the methods below and, if necessary, re-mark the rotor. • Models from 1969 on: use the timing plug on the left-hand crankcase • Use a degree disc on the crankshaft / camshaft (see table on page 6) • Use a dial guage down the spark plug hole (see table on page 6) 5. Remove kickstart, gear lever and outer timing cover. 6. Remove the contact-breaker plate and lead from the outer timing cover. 7. Taking the ignition trigger assembly, insert a small cable tie into the two holes in front of the connector block on the ignition trigger. This will be used later to secure the two wires to the plate. 8. Fit the ignition trigger plate with the adjustable slots at approx. 6 & 12 o’clock, using the original pillar fixings & washers, positioned in the centre of the slots (to allow for adjustment in either direction). Handle the trigger with care. • RED EARTHING WIRE • CRIMP CONNECTORS & INSULATORS • LARGE & SMALL CABLE TIES • CABLE TIE ADHESIVE MOUNTING BASE 3
9. Remove the centre bolt securing the auto-advance unit. Remove the complete auto-advance unit with an extractor bolt or by tapping it gently sideways. 10. Fit the magnetic rotor in place of the auto-advance unit, with the magnets/ red marks positioned at approx. 3 & 9 o’clock. The magnetic rotor has a male taper which fits into the taper in the end of the camshaft. There is no keyway, allowing it to be fitted in any desired position. 11. Using the ¼” washer and the appropriate bolt (UNF or BSF), pass the bolt through the centre of the magnetic rotor and into the thread in the camshaft. Finger tighten only at this stage. The magnetic rotor centre thread (metric M8) is provided for attaching a puller, if the rotor should need to be removed for engine servicing, etc. 12. Replace the outer timing cover, gear lever & kickstart. 13. Check that the engine is still at the correct full advance position, then adjust the magnetic rotor position so that one of the red marks is centrally behind the static timing hole at 9 o’clock (see fig. 4, page 7). If your machine’s camshaft rotates clockwise, refer to fig. 3. Gently tap the rotor into the taper & tighten the centre bolt, using a 3/16″ allen key. WIRING: 14. All connections must be of the highest quality, use crimped or soldered connections; twisted wires will not give a satisfactory operation. Avoid coiling up surplus lead.

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DYNA III ELECTRONIC IGNITION INSTALLATION INSTRUCTIONS

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Filed Under (Tips and Review) by admin on 27-10-2010

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1)Fasten the clamp to the electronic module using the 4-4O x 5/16 screws and lockouts provided. The damp and nuts go on the inside of the case. 2)Remove the fuel tank. Attach the module to the frame in the location selected. Cut off excess clamp material. 3)Remove an engine case or valve cover bolt and fasten the ground lug (black wire) securely to the engine. DO NOT ATTACH TO FRAME. 4])Locate the two ignition coils (they are positioned behind the left side cover on some models). There is a white wire going to the positive side of one coil that carries the switched 12 volts. A short blue/black wire then connects that point to the positive side of the other coil. Connect the separate red wire included with the kit to the spare spade terminal that is available on the positive terminal of the second coil. 5)Plug the red wire coming from the electronic module into the red wire installed in Step 4. 6)Remove the cap from the contact breaker housing. Remove the alternator cover, timing mark inspection plug, and spark plugs. 7)Remove the two screws and clips holding the points plate to the housing. Remove the screws holding the condensers to the housing. Disconnect the red and green wires where they plug into the wire harness (or coils), and remove the entire points/plate/condenser assembly. 8)Make sure the top of the housing is clean. Place the DYNA III sensor plate on the housing and orient it so that the wires exit to the rear. Place one of the original wire grommets on the front end of the plate and secure it with the screw and clip previously removed. Route the sensor cable wires through the other grommet (2 wires in the largest hole) and secure with the other screw and clip. Before tightening the plate screws, make sure the plate does not obstruct the cap screw holes. 9)Using a hex wrench in the alternator bolt, rotate the engine forward until the right hand cylinder is at top dead center on the compression stroke (D mark aligned with index mark on engine case). 10) Make sure the points cam is free of dirt and grease, and slip the DYNA III rotor over the cam Push the rotor down until it’s flange is in contact with the top of the cam. Orient the rotor so that the mark on top aligns with the line on the left (right cylinder) sensor. While pushing down on the rotor, tighten the set screws using the alien wrench supplied with the kit. 11)Rotate the engine by hand and check run-out (wobble) of rotor by watching the rotor/sensor gap. If the rotor is installed correctly, there should be no more than . 005 run-out, and it should not come in contact with either sensor. As a final check, turn the engine with the electric starter and observe the run-out. 12)Connect the three sensor cable plugs to the module receptacles, matching the red, white, and black wires. 13)Plug the remaining red and green wires onto the spade terminals where the original points connected, matching the colors

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