Accel Motorcycle Catalogue

Motorcycle Catalog

2013 Edition

Matrix Heatshield Mat PAGE 25 NEW PRODUCTS

Matrix Heatshield Wrap PAGE 25

High Temperature Exhaust Wrap PAGE 25

Starter Solenoids PAGE 19

Liquid Filled Oil Pressure Gauge PAGE 22

Power Pulse Coils PAGE 8

8mm S/S Wire PAGE 4-5

Aluminum Vise Jaws PAGE 27

TABLE OF CONTENTS

Spark Plugs . . . . . . . . . . . . . . . . . . 2-3

Spark Plug Wires, Custom Fit. . . . . . . . . . . . 4-5

Spark Plug Wires, Universal and Tools. . . . . . . . 6-7

Supercoils . . . . . . . . . . . . . . . . . . . 8-9

Ignitions and Distributors. . . . . . . . . . . . 10-11

Stators, Rotors and Charging System Kits . . . . . . 12-13

Voltage Regulators. . . . . . . . . . . . . . . 14-16

Generator Parts and Tune Up Kits. . . . . . . . . 17-18

Starters, Relays and Solenoids. . . . . . . . . . 19-21

Electrical Accessories and Switches . . . . . . . . 22-23

Brake Parts. . . . . . . . . . . . . . . . . . . 24

Exhaust Wrap/Heatshield . . . . . . . . . . . . . . 25

Mr. Gasket Shop Supplies. . . . . . . . . . . . 26-27

General Accessories and Promo Items. . . . . . . 28-29

Troubleshooting and Warranty. . . . . . . . . . 30-31

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1

SPARK PLUGS

High Performance Platinum Spark Plugs • Made from the finest materials available to ensure long trouble free operation • Premium quality platinum tip is more durable than other plug material • Maintains proper gap much longer than standard plugs • Pure copper center electrode for reduced fouling • Enjoy easier starting, smooth idling, and increased performance • Sold in 2 packs and 24 ct shop packs High Performance U-Groove Spark Plugs • Patented U shaped ground electrode produces a wider, hotter spark • Heavy duty 5 rib insulators prevent flashover • High quality copper/nickle alloy electrode • Highly foul resistant and dissipates heat better than any other material

• Improves engine efficiency and reduces emissions • Increases throttle response and reduced misfires

Engine

Year

Model

U-Groove Platinum ACCEL Ref. No. HD Ref. No. Champion Gap

Twin Cam 88 1340 Evolution

1999-2013 1983-1999

All

2418

Y2418P Y2410P Y2410P

882 496 496 116 496 116 137 137 882 882 882

6R12 5R6A 5R6A 5A6A 5R6A 5A6A

RA8HC RN12YC RN12YC RN12YC N12YC J12YC J12YC RA8HC RA8HC N12YC

0.04 0.04 0.04

FL, FX (All) FL, FX (All)

2410A 2410A 2403A

1340 Shovelhead 1980-1981 1340 Shovelhead 1975-1979

FL, FX

0.025

1200 Shovelhead 1979-1984 FL, FX (All) w/elect ign 2410A 1200 Shovelhead 1976-1978 FL, FX (All) w/o elec ign 2403A

Y2410P

0.04

0.025 0.025 0.025

1200 Shovelhead 1966-1975

FL, FX 3/8" Reach FL, FX 3/8" Reach

2401 2401 2418 2418 2418

3 3

Panhead

1948-1965 1986-2006 1986-1994

1200 Evolution 1100 Evolution

XLH Sportster XLH Sportster

Y2418P Y2418P Y2418P*

6R12 6R12 6R12

0.04

883 V-2 Evolution 1986-2013

XLH (All)

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SPARK PLUGS

Spark Plug Application by Family, Year, and Model Year Model

U-Groove Platinum

Sportster 1954-1970 1986-2013 Softail 1984-1999 1999-2013 Dyna 1971-1974 1975-1983 1984-2000 1999-2013 Touring 1948-1974 1975-1982 1983-1999 1999-2013

XS, XL, XLH, XLCH, XLS, XLX XS, XL, XLH, XLCH, XLS, XLX

2401

2418*

Y2418P*

FXST, FXSTS, FLST, FLSTC

2410A*

Y2410P* Y2418P*

All Twin Cam

2418*

FX, FXE, FXEF, FXWG, FXS FX, FXE, FXEF, FXWG, FXS FX, FXE, FXEF, FXWG, FXS

2401

2403A 2410A*

Y2410P* Y2418P*

All Twin Cam

2418*

FL, FLH FL, FLH FL, FLH

2401

2403A 2410A*

Y2410P* Y2418P*

All Twin Cam

2418*

* Denotes Resistor Plug Kit

Spark Plug Shop Packs 24 ct Description

P/N

2410A Spark Plugs

SP2410A SP2410P SP2418 SP2418P

2410P Spark Plugs (Platinum)

2418 Spark Plugs

2418P spark plugs (Platinum)

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3

SPARK PLUG WIRES

8mm S/S Spiral Core Wire • 8mm, 500 ohms per foot

• Designed specifically for Harley Twin Cam applications • Compatible with both carbureted and fuel injected systems • Maximum RFI protection shields sensitive electronics • Up to 5 times more peak energy than other “performance”wires • Available in 4 colors- blue, black, red, and yellow • Custom fit sets are ready to install, no cutting or splicing required

300+ Race Wire • 8.8mm, 150 ohms per foot

• Designed specifically for race-winning or maximum street performance • Compatible with both factory and aftermarket electronic ignitions and points • Delivers peak performance even at temperatures over 550 degrees • 8mm sets available for carbureted Twin Cam applications, not recommended for EFI systems • Available in both ready to install custom fit sets and universal kits • Gloss black 8.8mm Suppression Core and Stainless Core Wire • 8.8mm, Yellow or Black • Designed for high performance street or racetrack use • Stainless steel terminals with premium quality silicone boots • Suppression core features maximum RFI protection for electronic ignitions

• Use stainless core wire with points or magneto ignitions only • Available in both ready to install custom fit sets and universal kits

4

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SPARK PLUG WIRES

Custom Fit Wire Sets-Ready to Install Year Model

300+

8.0 S/S

8.8 Yellow 8.8 Black

Buell

1996-1998 1999-2008 1999-2008 1958-1969 1971-E1978 1979-1985 1979-1982 1986-2006 1998-2003 2004-2006 2007-2012 2009-2012 1984-1990 1991-1999 2000-2008 2000-2012 1971-E1978 L1978-1984 1982-1994 1983-1984 1985-1986 1999-2005 1999-2012 1965-E1978 L1978-1984 1980-1984 1985-1998 1994-1998 1999-2008 1999-2008 2009-2012 1985

All Models

175096^ 175097^

All Models w/Carb

All Models

171097-B,K,R,Y #

Sportster

XL, XLCH (with Magneto)

172075* 172074* 172072* 172072* 172086

172075K* 172074K* 172072K* 172072K* 172086K

XLH, XLCH

175074 175074 175074 175086

XL, XLCH, XLX

XLS

XL Models

Sportster Sport w/Twin Plug

175099^

XL Models XL Models

171098-B,K,R,Y# 171110-B,K,R,Y# 171112-B,K,R,Y#

XR1200

Softail

Softail ® Models Softail ® Models

175074 175089

172072 172089

172072K* 172089K

Softail ® Models w/carb

175100^

Softail ® Models w/carb or EFI

171100-B,K,R,Y#

Dyna

FX,FXE

175073 175073 175082 175073 175074 175074

172073* 172071 172082 172071 172072 172072

172073K* 172071K 172082K 172071K

FX, FXE-80, FXS FXR, FXRS, FXRT

FXWG

FXEF, FXSB

72072K 72072K

FXWG

FXD Carb only FXD Carb or EFI

175097^

171097-B,K,R,Y #

Touring

FL, FLH

175073 175073

172073* 172071 172083 172090

172073K* 172071K 172083K 172090K

FLH

FLT, FLHT, FLHTC, FLTC

FLT, FLHT Models

175090

FLHR

175091^ 175098^

All w/carb

All w/carb or EFI

171098-B,K,R,Y# 171111-B,K,R,Y#

All Models

^All Twin Cam kits use 8mm wire

* Stainless Steel Core-Not for Electronic Ignition Use

# B=Blue, K=Black, R=Red, Y=Yellow

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5

UNIVERSAL WIRE

5mm Thundersport Universal Wire Sets • 5mm diameter wire/150 ohms per foot • Rated to handle in excess of 60,000 volts • Extremely flexible allowing for custom routing • Set includes two 60”leads • 90 deg plug boots and straight coil boots • A favorite of custom bike builders everywhere • Not for use in Twin Cam applications

5mm Black

5mm Yellow

5mm Blue

5mm Red 173087-R

173087-K

173087-Y

173087-B

173087-Y

8.8mm Universal Wire Sets • Premium quality ACCEL 8.8mm ignition wire in universal kits

• Available for 2 and 4 plug applications for electronic and points type ignitions • Pre terminated with either a 90 deg or variangle heavy duty spark plug boots • 2 plug kits contain one 42”wire, brass terminals, coil boots and instructions • 4 plug kits contain two 42”wires, brass terminals, coil boots and instructions • The ultimate in performance and reliability for street and racing use

Number of Spark Plugs Plug Boot

8.8mm Yellow 173085 173083

8.8mm Black

8.8mm Yellow*

Black 300+

2 2 4 4

Variangle

175095 175093

173085K 170083* 173083K 170085* 173084K 170082*

90 deg

173082

Variangle

90 deg

173082

173082K

* Copper core for points/magneto ignitions only.

Spooled Spark Plug Wire • 60 foot spools of Premium Quality ACCEL wire • Perfect for production shops and custom builders

Description

P/N

8.8mmYellow Suppression CoreWire 60 ft spool 8.8mm Black 300+ RaceWire 60 ft spool

160096M 160097M

160096M

160097M

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WIRE PARTS

300+ Professional Crimping Tool • Best wire crimping tool available • Heavy duty hardened steel frame with non-slip grip • Adjustable ratchet mechanism produces consistent factory crimps • Complete with 3 removable stripping/crimping die jaws • Compatible with 7-9mm plug wires and primary wire terminals

Description

P/N

300+ Professional Crimping Tool with 3 die set

170036M

160096M

Superstock Crimping Tool • Features a strong steel frame and cushioned hand grip • Strips spark plug wires and crimps 7-8mm terminals • Produces a factory style crimp

Description

P/N

170037

Superstock Crimping Tool

170037

Spark Plug Gapping Pliers • Accurately and consistently gap spark plugs • Adjustable from .030”to .080” • Features a strong steel frame and cushioned hand grip

Description

P/N

Spark Plug gapping Pliers

380700

380700

Terminal and Boot Packs • Perfect match for our 8.8mm spooled wire • Sold in packs of 10 terminals and boots

22946

Wire Size P/N 8.8-9mm 22911 8.8-9mm 22946 7-8mm 24170 8.8-9mm 24130 8.8-9mm 24140 7-8mm 24150

Type

Description

Spark Plug Spark Plug Spark Plug Ignition Coil Ignition Coil Ignition Coil Ignition Coil

90 degree Variangle 90 degree

24150

22911

Straight

24140

90 degree

Straight

Straight Twin-Cam 7-8mm 24160

22160

24130

24170

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7

SUPERCOILS

ACCEL Super Coils • The standard by which other coils are measured • Faster rise times, higher voltage, and maximum spark energy to the plug • Delivers up to 45%more voltage than OE coils • Available for both electronic and points triggered ignitions • Designed to fit in stock locations and under most coil covers • Covered by ACCEL’s famous limited Lifetime Replacement Warranty

140410

Twin Cam Super Coils

Fuel System

Primary Resistance

Black P/N 140409 140409 140410 140410 140410

Replaces HD P/N 31655-99 31655-99 31743-01 31743-01 31743-01

Year

Model

2004-2006 1999-2006 2001-2006

XL

Carburetor

0.5 Ohms 0.5 Ohms

Twin Cam Carburetor

Softail

Fuel Injected 0.5 Ohms Fuel Injected 0.5 Ohms Fuel Injected 0.5 Ohms

2004-2005, 2011

Dyna

2002-2007

Touring

140409

Dual Fire Super Coils

Ignition Type Points Type Electronic

Primary Resistance

Yellow P/N 140406 140407

Black P/N

Chrome P/N

Year

Model

1965-1979 1980-1998

All All

4.7 Ohms 2.3 Ohms

140406BK 140406CH 140407BK 140407CH

Single Fire Super Coils

140406

Ignition Type Single Fire

Primary Resistance

Yellow P/N 140408

Black P/N

Chrome P/N

Year

Model

1936-2006 All except TC

3.0 Ohms

140408BK 140408CH

Power Pulse Coil

Ignition Type

Primary Resistance

Yellow P/N 140402

Black P/N

Year

Model

1965-1979 1984-1999 1985-2003

All 12 Volt All Big Twin

Points

4.2 Ohms 3.0 Ohms 3.0 Ohms

140402BK 140401BK 140401BK

140408BK

Electronic Electronic

Sportster

140408CH

140401BK

140402

8

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UNIVERSAL COILS

Universal Super Coils • High output coils available for 2 and 4 cylinder motorcycles • Available for both points style and electronic ignitions • Kits include mounting brackets and high quality 8.8mm suppression core wire • Get maximum performance for older motorcycles • Available for Harley Davidson and most metric models • Please see note below to determine the appropriate coil for your application

Super Coil Kits for Harley Davidson®

Primary Resistance

Ignition Type

Yellow P/N 140405

Black P/N

Year

Model

1965-1977

XL, FL, FX

3.0 Ohms

Points

140405K

XL, FL, FX except Single fire and Twin Cam

1978-1999

3.0 Ohms

Electronic

140405

140405K

Super Coil Kits for Universal Applications

Ignition Type

Primary Resistance

Yellow P/N 140403S 140403 140404S 140404

Black P/N

Model

2 Cylinder (1 Coil Kit) 4 Cylinder (2 Coil Kit) 2 Cylinder (1 Coil Kit) 4 Cylinder (2 Coil Kit)

Inductive (non Capacitive Discharge) Inductive (non Capacitive Discharge)

3.0 Ohms 3.0 Ohms .7 Ohms .7 Ohms

140403KS 140403K 140404KS

Capacitive Discharge Ignition Capacitive Discharge Ignition

140404K * NOTE: Please test your OEM coils to verify they are within (+/-) 10% of noted ACCEL coil specifications. Using the wrong coil may damage your motorcycle’s electronic ignition module. To determine the ignition type, perform the following test: 1. Determine that the coil you are replacing is a twin tower coil. (These coils will not replace single tower coils). 2. Using a volt meter or 12 volt test light, hook positive lead to position post and negative to ground on one of the stock coils. 3. Turn on ignition but DO NOT engage the starter button. 4. If there are 12 volts at the coil, the motorcycle has inductive type ignition. If there is no voltage at the coil then the motorcycle has a capacitive discharge ignition (CDI) because the power goes to the control box first.

140403K

140403

140403S

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9

IGNITIONS

Single/Dual Fire Ignition • Machined Aluminum housing offers superior heat sink capabilities • Single fire or dual fire compatible when matched with the appropriate coil • Rugged billet aluminum construction is vibration and moisture proof • Fully adjustable for stock engines to highly modified machines • Made in the USA

Year

Model

P/N

1970-1983 1984-1999 1971-1982 1993-2003

Big Twin Models with timing rotor Big Twin Models except Twin Cam Sportster Models with timing rotor

35496 35496 35496 35496

Sportster Models

35496

Super Single Fire System • Finally a complete ignition system in one box, no more mixing and matching components • Includes 35496 ignition module, 140408 single fire Super Coil, 8.8mm wires and U-Groove spark plugs • Fully adjustable with 14 pre programmed advance curves. • Features on board rev limiting and an LED light for easy static timing • Everything you need to upgrade from early points systems or update the non adjustable OEM electronic unit

Year

Model

P/N

1971-1982 1983-2003 1970-1983 1984-1999

Sportster Models with timing rotor

35410 35410 35410 35410

35410

Sportster Models

Big Twin Models with timing rotor Big Twin Models except with Twin Cam

10

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DISTRIBUTORS Electronic Advance Distributors with Rev Limiting Module • Finally a modern electronic ignition for early distributor equipped Big Twins and Sportsters • Single fire or dual fire compatible when matched with the appropriate coil • Fully adjustable with 14 pre programmed advance curves. • Features on board rev limiting and an LED light for easy static timing • Machined Aluminum housing offers superior heat sink capabilities • Can be installed without engine disassembly when stock cylinders and

heads are used • Made in the USA

Year

Model

P/N

1936-1969 1952-1970

Big Twin Models Sportster Models

A557 A577

A577

E-Spark Distributors • Performance and reliability at an affordable price • Bullet proof, fully adjustable mechanical advance • Utilizes the rugged Mallory E-Spark Ignition Module • Can be used with kickstart applications • Can be installed without engine disassembly when stock cylinders and heads are used • Made in the USA

Year

Model

P/N

1936-1969 1952-1970

Big Twin Models Sportster Models

A556 A576

A556

E-Spark Breakerless Conversion Kits • Simple conversion from breaker points in Big Twin and Sportster models • Utilizes the rugged Mallory E-Spark Ignition Module • Self contained E-Spark module has no moving parts to wear out • Simple 3 wire connection for easy installation • Requires a 2.0-3.0 ohm coil for racing and a 3.0-4.0 ohm coil for street use

Year

Model

P/N

1970-1978 Big Twin Models

A554 A554 A566

1979-1995 Big Twin Models converted to points and mechanical advance

1971-1978 Sportster Models

A554

Replacement E-Spark Module • Replacement module available for both E-Spark distributors and E-Spark Breakerless Conversion kits

Year

Model

P/N

All

E-Spark Distributors and Conversion Kits

A605

A605

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11

STATORS

Lectric Stators • Precision machine wound using only the finest components • Pure copper windings are coated with a high temperature insulation to protect from grounding • Designed for maximum output and dependable reliability • All applications feature factory style connectors for plug and play installation • Covered by ACCEL’s famous Limited Lifetime Replacement Warranty

Year

Model

OEM P/N

Charging System Connector

ACCEL P/N

Sportster

1985-1990 1990-1995 1991-2000 1985-1988 1985-1988 1989-1999

All Sportster All Sportster All Sportster

29967-84 29967-84A 29967-89A 28865-81 28865-81A 29970-88A 29951-99 30017-01 30017-07 29970-88A 29951-99 30017-01 30017-07 29965-70 29965-75 28865-81 28865-81A 29970-88A 29987-97 29987-99 29987-02 29987-06

19 Amp Alternator 19 Amp Alternator 22 Amp Alternator 22 Amp Alternator 22 Amp Alternator 32 Amp Alternator 32 Amp Alternator 38 Amp Alternator 40 Amp Alternator 32 Amp Alternator 32 Amp Alternator 38 Amp Alternator 40 Amp Alternator 15 Amp Alternator 17.8 Amp Alternator 22 Amp Alternator 22 Amp Alternator 38 Amp Alternator 38 Amp Alternator 45 Amp Alternator 32 Amp Alternator ex. EFI 50 Amp Alternator-3 Phase

E E E

152105* 152106 152108 152103* 152104 152107 152109 152111 152112 152107 152109 152111 152112 152101 152102* 152103* 152104 152107 152110 152113 152114 152115

Softail

All All All All All All All All All All All All All All All

B B D

2000

L

2001-2006

W W

2007

Dyna

1991-1999 2000-2003 2004-2006

D

L

W W

2007

Touring

1970-1975 1976-1980 1981-1988 1981-1988 1989-1999 1997-2001 1999-2001 2002-2005 2006-2009

C A B B D

FLHT

M

FLHR, FLT

L

All All

V U

*Indicates molded style stator

Note: See page 15 for connector images

152106

154104

12

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ROTORS & CHARGING SYSTEM KITS

Lectric Rotors • Heavy duty replacement rotors • High quality magnets enclosed by stainless steel • Reinforced housing and splines for the ultimate in durability • Perfect compliment to our Lectric Stators Softail 1991-2000 Ex Twin Cam 29957-81 32 Amp Alternator 2000-2006 Twin Cam 29981-95 38 Amp Alternator Dyna 1991-1999 Ex Twin Cam 29957-81 32 Amp Alternator 2000-2003 Twin Cam 29957-81 38 Amp Alternator 2004-2005 Twin Cam 29981-95 38 Amp Alternator Touring 2000-2005 Twin Cam 29981-95 38 Amp Alternator Lectric Charging System Kits • High quality ACCEL stator, rotor, and regulator in one complete kit • Perfect for OE replacement or to upgrade earlier systems • Features ACCEL’s famous lifetime replacement warranty Year Model

OEM P/N Charging System P/N

152100 152201

152100 152100 152201

152100

152201

Year P/N 1970-1984 32 Amp upgrade for all alternator Shovelheads and Evo big twin applications 152300 1991-1999 32 Amp System for all EVO Softail and Dyna Big Twins except Twin Cams 152300 2001-2006 38 Amp System for all Twin Cam equipped Softails 152304 Description

152304

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13

VOLTAGE REGULATORS

Hybrid Design Electric Voltage Regulators • Produced with Heavy Duty solid state circuitry and years of technology • Quality and reliability that you can depend on • All applications feature factory style connectors for plug and play installation • Available in show chrome and textured black finishes • Covered by ACCEL’s famous limited Lifetime Replacement Warranty

Year

Model

Comments

OEM P/N

Black P/N Chrome P/N Connector

Sportster

1967-1977 1977-1981 1982-1984 1984-1990

All Sportster All Sportster All Sportster All Sportster All Sportster All Sportster All Sportster

w/12V Generator w/12V Generator w/12V Generator

74510-65, 74510-64, 74507-85A 201104B

201104C 201102C 201117C 201121C 201123C 201130C 201137C 201122C 201124C 201126C 201131C 201100C 201101C 201118C 201118C 201118C 201122C 201125C 201126C 201132C 201133C 201100C 201101C 201118C 201122C 201127C 201127C 201134C 201135C 201136C 201118C 201118C

I/1 J/1 K/1 E/1 E/1 F/1 P/1 D/1 G/1 H/2 O/2 C/1 A/1 B/1 B/1 B/1 D/1 G/1 H/2 Q/4 N/4 C/1 A/1 B/1 D/1 G/3 G/3 S/3 R/3 T/3 B/1 B/1

74504-78 74504-82 74523-84A 74523-91 74523-94 74523-04 74519-88 74512-00 74540-01 74540-07 74510-70A 74512-79A 74516-86 74516-86 74513-82A 74519-88 74518-99A 74540-01 74631-04 74631-06

201102B 201117B 201121B 201123B 201130B

W/19 Amp Alt w/22 Amp Alt w/22 Amp Alt w/22 Amp Alt

1991

1994-2003 2004-2006

Softail

1986-1988

All

w/22 Amp Alt

74515-86, 74512-84, 74513-85, 74516-86, 74513-82A

201118B

1989-1999

All All All All

w32 Amp Alt w/38 Amp Alt w/38 Amp Alt

201122B 201124B 201126B

2000

2001-2006

2007

Dyna

1970-1975 1976-1980 1981-1985 1981-1986 1982-1988 1989-1999 2000-2003 2004-2005 2006-2007 1970-1975 1976-1980 1981-1984 1989-1999 1997-2001 1999-2001 2002-2003 2004-2005 2006-2008 1999 1981-1988

FX, FXE

w/15 Amp Alt w/17.8 Amp Alt w/22 Amp Alt w/22 Amp Alt w/22 Amp Alt w/32 Amp Alt w/38 Amp Alt w/38 Amp Alt

201100B 201101B 201118B 201118B 201118B 201122B 201125B 201126B

FX, FXE, FXS, FXEF

FX, FXE, FXEF

FXWG

FXR, FXRS, FXRP, FXRT

All

All Twin Cam

All All All

w/45/60 Amp Alt

Touring

FL

w/15 Amp Alt w/17.8 Amp Alt w/22 Amp Alt

74510-70A

201100B 201101B 201118B

FL, FLH, FLT

74510-75A, 74512-79, 77510-75 74515-86, 74512-84, 74513-85, 74516-86, 74513-82A 74515-86, 74512-84, 74513-85, 74516-86, 74513-82A

FLH 80

FLT, FLHT

w/22 Amp Alt

201118B

All Evo Ex EFI, 97up FLT

w/32 Amp Alt w/38 Amp Alt w/38 Amp Alt

74519-88 74505-97 74505-97 74505-02 74505-04 74505-06

201122B 201127B 201127B

FLHT

FLHR, FLT

All All All

14

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VOLTAGE REGULATORS

E

C

D

A

B

I

F

G

H

N

M

L

O

J

K

Q

T

P

R

S

U

1

V

W

1

Chrome

Original Equipment Style

2

3

4

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VOLTAGE REGULATORS Electro-Mechanical Voltage Regulators (Delco ® Type) • Provides precise control of charging system voltage for maximum performance and reliability • Built with high quality components set to OEM factory specifications • Available in show chrome or black enamel finishes

Engine Size OEM P/N

Charging System

Black P/N

Chrome P/N

Year

Model

6 Volt Generators 1952-1964

K, XL

900cc

74510-47A 6V Generator 74510-47A 6V Generator

201106C 201106C

1958-1964

FL, FLH 1200cc

12 Volt Generators 1965-1969

FL, FLH 1200cc

74510-64 12V Generator 201105 201105C 74510-64 12V Generator 201105 201105C

201105

1965-1977

XLH

1200cc

Electro-Mechanical Voltage Regulators (Bosch ® Type) • Provides precise control of charging system voltage for maximum performance and reliability • Built with high quality components set to OEM factory specifications • Available in show chrome or black enamel finishes

Engine Size

Charging System

Black P/N

Chrome P/N

Year

Model

OEM P/N

1965-1966 1965-1977

XLH

900cc

74511-65 12V Generator 201107 201107C 74511-65 12V Generator 201107 201107C

201107

XLCH 900cc/1000cc

Universal Regulator Mounting Bracket • Universal Stainless Steel Mounting bracket • Allows for use of an electronic voltage regulator on early models

Description

P/N

Universal Regulator Mounting Bracket-304 Stainless Steel

151100

151100

16

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GENERATOR PARTS Generator Parts • Engineered for peak charging system output on demand • Armatures and field coils utilize heavy gauge copper windings • Brush sets utilize precision ground carbon graphite and premium grade springs • Overhaul kits contain brushes, quality oil seal and cover gasket

Armatures Year 1965-1969 1965-1971

Model FL, FLH

OEM P/N

Gen Model

Voltage P/N

30851-65A 64,65,65A, 2 Brush 12 Volt

151301 151301 151301

XL, XLH, XLCH 30851-65A 64,65,65A, 2 Brush 12 Volt

151301

1972-1981 XLH, XLCH, XLT, XLS 30851-65A 64,65,65A, 2 Brush 12 Volt

Field Coils Year

Model FL, FLH

OEM P/N

Gen Model

Voltage P/N

1965-1969 1965-1971

30201-65 64,65,65A, 2 Brush 12 Volt 30201-65 64,65,65A, 2 Brush 12 Volt

151303 151303 151303

XL, XLH, XLCH

1972-1981 XLH, XLCH, XLT, XLS 30201-65 64,65,65A, 2 Brush 12 Volt

151303

Brush Sets Year

Model

OEM P/N Gen Model

Voltage P/N

1932-1952 G,W,WL,WLA,f/Head 45ci 1937-1947 U,UL,Flathead 74ci

30425-32 30425-32

32 32

6 Volt 6 Volt

192302 192302 192302 192302 192302 192300 192300 192300 192300

1937-1948

UH, UHL Flathead

30425-32 32 3 Brush Gen only 6 Volt

1941-1947 E, F, FL Knucklehead 30425-32

32 32

6 Volt 6 Volt 6 Volt 6 Volt

1948-1952 1958-1964 1958-1964 1965-1969 1965-1981

FL, FLH Panhead

30425-32 30426-58 30426-58 30426-58 30426-58

XL, XLH, XLCH

58, 61 58, 61 58, 61 58, 61

FL, FLH FL, FLH

192302

12 Volt 12 Volt

XLH, XLCH, XLS

Overhaul Kit Year

Model

Gen Model

Voltage

P/N

1958-1960

XL, XLH, XLCH

58 58 61

6 Volt 6 Volt 6 Volt

192303 192303 192303 192303

1958

FL, FLH

1961-1964 1965-1969

XL, XLH, XLCH

FL, FLH

64,65,65A

12 Volt

192303

technical service 216-658-6429

17

TUNE-UP PARTS

Advance Weight Assembly • Replace that aging, inadequate advance mechanism with this premium quality ACCEL assembly • Perfect for OE replacement or a performance upgrade • Complete with precision ground breaker cam and installation instructions

Year

Model

Application

P/N 8506 8506

1970-E1978 1971-E1978

FL

Performance Upgrade or Repair Performance Upgrade or Repair

FX, XL

All Harley® Twins w/ Electonic Ign. (ex. TC)

L1978-1999

Conversion to Points

8506

8506

Performance Tune-Up Kits • Performance 32 oz points and premium quality condenser in one kit • Designed for peak ignition performance and reliable service • Available with or without performance U-Groove spark plugs

Year

Model

Tune Up Kit

Kit with Spark Plugs

1948-1969

1200 cc (74ci)

8401

8406

900cc (55ci) XLCH w/Mag

1958-1969

8402

1970-E1978 1971-E1978

FLH, FX

8400 8400

8408 8411

XL

8406

Performance Points and Condensers • Built using premium quality materials for long life

• 23 oz points are suitable for OE replacement in stock applications • 32 oz high performance points eliminate points bounce and float • High capacitance condensers are designed to provide extended point life

Year

Model

OEM P/N

P/N

Point Sets 1970-E1978 1970-E1978 1970-E1978 1970-E1978 1971-E1978 1971-E1978 Condenser 1941-E1978 1941-E1978 1954-E1978

FL, FLH (standard 23oz) FL, FLH (high perf 32oz)

32661-70 32661-70 32661-70 32661-70 32661-70 32661-70 32726-30A 32726-30A 32726-30A

111129 111130 111129 111130 111129 111130 111131 111131 111131

FX (standard 23oz) FX (high perf 32oz)

111129

XL, XLCH (standard 23oz) XL, XLCH (high perf 32oz)

FL, FLH

FX XL

111131

18

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STARTERS

Ultra Tork Starters • Top quality starters using nothing but the best components • Available in 1.4 kw and 1.8 kw to start even the biggest V-Twins • Choose from show quality chrome and stealth black finishes • Backed by an unequaled 5 year warranty

Year

Model Softail Softail Softail

Description

Chrome P/N Black P/N

40002C

1994-2006 1994-2006 2007-2010 1994-2005 1994-2005 2006-2010 1994-2010 1994-2010 2007-2010

1.4Kw Starter w/Lifetime Clutch 1.8Kw Starter w/Lifetime Clutch 1.4Kw Starter w/Lifetime Clutch 1.4Kw Starter w/Lifetime Clutch 1.8Kw Starter w/Lifetime Clutch 1.4Kw Starter w/Lifetime Clutch 1.4Kw Starter w/Lifetime Clutch 1.8Kw Starter w/Lifetime Clutch 1.4Kw Starter w/Lifetime Clutch

40001C 40002C 40005C 40001C 40002C 40005C 40001C 40002C 40005C 40003C 40006C

40001B

40005B 40001B

Dyna Dyna Dyna

40003C

40005B 40001B

Touring Touring Touring

40005B

1974-1988 All Big Twin, XLH

All with Hitachi Type

1989-1993 1966-1982

All Big Twin

1.4Kw Starter w/Lifetime Clutch

40006B

40005B

FL, XL

All with Prestolite Type 1.0Kw 40004C

Starter Solenoids • Heavy duty replacement quality

Year

Model

OEM P/N Zinc P/N Chrome P/N Black P/N

SINGLE BRACKET FITS 4 SPEED MODELS Sportster 1967-1978 XLH, XLCR, XLT 71469-65B 40111

• Designed to deliver positive starter engagement every time • Hardened steel plungers and moisture proof cases are used for maximum durability • Available in show quality chrome, stealth black and zinc plate

40111C 40111C

40111B 40111B

1979-1980

XL

71469-65B 40111

Softail

1984-1988

FXST

71469-65B 40111

40111C

40111B

Dyna 1971-1985 FXE, FXEF, FXS 71469-65B 40111

40111C

40111B

FXE-80, FXEF-80, FX80

1979-1985

71469-65B 40111

40111C

40111B

1980-1985 1983-1985 1985-1986

FXB

71469-65B 40111 71469-65B 40111 71469-65B 40111

40111C 40111C 40111C

40111B 40111B 40111B

FXSB

FXWG

Touring 1965-1984 FL, FLH (Ex. FLT) 71469-65B 40111

40111C

40111C

40111B

DUAL BRACKET FITS 5 SPEED MODELS Dyna 1982-1988 FXR

40111B

31489-79B 40114 31489-79B 40114

40114C 40114C

40114B 40114B

1984-1988

FXRP

Touring

1980-1988 1984-1988

FLT

31489-79B 40114 31489-79B 40114

40114C 40114C

40114B 40114B

40114C

FLT Classic

technical service 216-658-6429

19

STARTERS

Starter Solenoid Repair Kits • Complete kit contains all the parts necessary to rebuild an OE or ACCEL solenoid • Includes plunger, lugs, spring assembly, bakelite cap and hardware • Rebuild for a fraction of the cost of new

Year

Model

Description

P/N

Sportster

1967-1978 1979-1980

XLH, XLCR, XLT

Repair Kit for OEM 71469-65 and 31489-79B Repair Kit for OEM 71469-65 and 31489-79B

40112 40112

XL

Softail

1984-1988

FXST

Repair Kit for OEM 71469-65 and 31489-79B

40112

Dyna

1971-1985

FXE, FXEF, FXS

Repair Kit for OEM 71469-65 and 31489-79B Repair Kit for OEM 71469-65 and 31489-79B Repair Kit for OEM 71469-65 and 31489-79B Repair Kit for OEM 71469-65 and 31489-79B Repair Kit for OEM 71469-65 and 31489-79B Repair Kit for OEM 71469-65 and 31489-79B Repair Kit for OEM 71469-65 and 31489-79B Repair Kit for OEM 71469-65 and 31489-79B Repair Kit for OEM 71469-65 and 31489-79B Repair Kit for OEM 71469-65 and 31489-79B

40112 40112 40112 40112 40112 40112 40112 40112 40112 40112

1979-1985 FXE-80, FXEF-80, FX80

1980-1985 1983-1985 1985-1986 1982-1988 1984-1988 1965-1984 1980-1988 1984-1988

FXB

FXSB

40112

FXWG

FXR

FxRP

Touring

FL, FLH (ex. FLT)

FLT

FLT Classic

Starter Relay • Durable heavy duty contacts in a rugged molded case • Totally sealed from moisture and road grime • Reliable starting

Year

Model

OEM P/N P/N

Sportster

1975-1979

XLH, XLT, XLCR XL, XLCH, XLS

71463-73C 71463-73C

40110 40110

1979

Softail

1985

FXST, FXSTC

71463-73C

40110

Dyna

1973-1979

FX

71463-73C 71463-73C 71463-73C 71463-73C 71463-73C 71463-73C 71463-73C

40110 40110 40110 40110 40110 40110 40110

1979

FXE-80, FXEF-80, FX-80

L1984-1985

FXRS, FXRP, FXRT FXSB, FXEF, FXWG

1985

Touring 1974-1979 FL,FLH, FLH-80, FLH Classic

40110

1979

FLT

L1984-1985

FLTC, FLHTC

20

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STARTERS

Starter Relay (Bosch ® Style) • Injection molded case eliminates corrosion for increased durability • Relays designed to work in high performance applications • Works great in stock bikes too

Year

Model

OEM P/N

P/N

Sportster

1980-1992

XL

31506-79B

40116

Softail

1986-1994

All Softail

31506-79B

40116

Dyna

1980-1984

FX

31506-79B 31506-79B 31506-79B 31506-79B 31506-79B 31506-79B 31506-79B

40116 40116 40116 40116 40116 40116 40116

E1984

FXRS, FXRT

1986

FXWG

1991-1994

All Dyna

Touring

40116

1980-1984

FL

E1984

FLTC, FLHTC

L1985-1994

FLT

31506-79B (Sound & Intercom system front speaker relay)

1989-1994 FLTC-U, FLHTC-U

40116

Starter Drive • Severe duty starter drives are designed for strength and durability • Five roller clutches and hardened receivers provide smooth reliable starter engagement

• Corrosion resistant stainless steel springs eliminate binding • Precision ground gears last longer and prevent ring gear damage

Year

Model

OEM P/N

P/N

Sportster 1967-1980

XL

31443-65B

151304

Softail 1965-1988 All Softail 1991-2006 All Softail Dyna 1965-1988 FX, FXR 1991-2005 All Dyna

31443-65B

151304 151306

151304

31663-90 Late 1.2Kw and 1.4Kw

31443-65B

151304 151306

31663-90 Late 1.2Kw and 1.4Kw

Touring 1965-1988

FL, FLT

31443-65B

151304 151306

1991-2006 All Touring

31663-90 Late 1.2Kw and 1.4Kw

151306

technical service 216-658-6429

21

ELECTRICAL ACCESSORIES

Liquid Filled Oil Pressure Gauge • Premium quality 1/8”NPT rear mount oil pressure gauges • Solid brass internals are bathed in vibration dampening glycerin • Stainless steel bodies are available in polished and new Stealth Black

Range 0-60PSI

Description

Polished P/N

Black P/N

Oil Pressure Gauge Oil Pressure Gauge

7121A

7121B 7122B

0-100 PSI

7122

7121B

4 Gauge Gold Battery Cable Sets • 4 gauge cable features 1667 strands of tin plated copper for extreme flexibility • Ends are terminated with top of the line gold plated terminals • Jacketed with high temperature translucent black silicone • Kit includes two OE length cables • Covered by ACCEL’s famous Limited Lifetime Replacement Warranty

Year

Model

P/N

151401

1989-2007 1991-2007 1991-2003 2004-2005 1991-2007

All Softail

151405 151401 151409 151408 151403

All Sportster

All Dyna All Dyna

FLT, FLHT, FLHS, Road King 5 Speed

Battery Eliminator • Boost spark voltage at cranking and eliminate flickering lights • For use with magneto and generator systems only • Includes shock resistant mounting clamp and hardware

Description

P/N

All batteryless systems

151308

151308

22

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SWITCHES

Oil Pressure Switch • Protect your valuable engine with a reliable oil pressure switch • Our stringent quality control standards assure accurate pressure every time • Heavy duty contacts, brass ferrules and corrosion resistant plated steel shells are used for durability

Year

Model

OEM P/N

P/N

Sportster

L1977-1992

XL

26554-77

181103

Dyna

FX, FXE, FXS1200, FXEF-80, FXS-80, FXB-80, FXWG-80

1971-1984

26552-72

181102

1982-1983 1984-1985 1984-1986 1986-1992 1991-1998

FXR, FXRS, FXRT

26552-72 26561-84 26561-84 26561-84 26561-84

181102 181104 181104 181104 181104

FXRS, FXRT

All FX

181102

All FXR

All Dyna

Softail

1984-1999

All Softail

26561-84

181104

Touring

1941-1984 1980-1983 1984-1985

FL, FLHT, FLH-80

26552-72 26552-72 26561-84

181102 181102 181104

FL, FLHT

FLT Classic, FLHT Classic

Stop Light Switches • Heavy duty contacts and high conductivity brass terminals • Bright plated housing with rugged molded insulators • Reliable performance for all conditions

Year

Model Servi Car

Engine Size 750cc/45 ci 1200cc/74 ci 1200cc/74 ci

OEM P/N 72002-51A 72002-51A 72023-51A 72023-51A 72023-51A 72023-51A 72023-51A 72023-51A

P/N

181100

1951-1973 1958-1970 1971-1972 1971-1984 1979-2003 L1979-1983 1982-1983 L1984-2007

181100 181100 181101 181101 181101 181101 181101 181101

FL, FLH

FX FL XL FX

1200cc/74 ci, 1340cc/80 ci 883cc, 1000cc, 1100cc 1200cc/74 ci, 1340cc/80 ci

FXR

1340cc/80 ci

181101

All except XL

1340cc/80 ci, 1450cc/88 ci

technical service 216-658-6429

23

BRAKE PARTS

Wheel Cylinder Repair Kits • Premium grade SBR cups and end seals • Unique patented compression spring eliminates the need for cup extenders • Restore your wheel cylinders to proper operation

Year

Model FL, FLH FL, FLH

OEM P/N 41748-58 41748-63 41748-63

P/N

1958-196 1963-1972 1971-1972

33004 33007 33007

FX

33007

Bleeder Screws • Bleed your brake lines to eliminate spongy brakes • Great for replacing rounded or stripped OEM bleeder screws • Precision machined and available in 10 packs

Year

Model

OEM P/N 41749-58 41749-58 41749-58 41749-58

P/N

1951-1973 1958-1962 1972-1979 1973-1977

Servi-Car 45 (wheel cylinder 2 required)

33001 33001 33001 33001

FL, FLH (wheel cylinder) FL Series (disc brake caliper) XL Series (disc brake caliper)

33001

Straight High Flow Fuel Spigot • Assure your bike isn’t starving for fuel • Recommended for any bike with performance modifications • Built in 100 micron screen filter • 3 position On/Off/Reserve • Show quality chrome

Description

P/N 5105 5106 5107

1971-up All V-Twins with Carburetors-Straight

1971-up All V-Twins with Carburetors-Rotates Horizontialy 1971-up All V-Twins with Carburetors-Rotates Vertically

5105

24

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EXHAUST WRAP Matrix Heatshield Wrap • The latest in heatshield technology • Woven from crushed volcanic rock or “Basalt” • Naturally chemical and weather resistant • Stronger and more durable than fiberglass wraps • Improved thermal performance and reliability

• Trick high gloss carbon fiber look and feel • 100% asbestos free and noncombustible • Complete kits include (4) 14”stainless steel ties and detailed instructions

2002MW

Description 2" Complete Kit 1" Complete kit

Length 2" x 25' 1" x 50' 2" x 25' 1" x 50'

Matrix 2002MW 2001MW 2002BM 2001BM

2" Wrap only 1" Wrap only

2002SS

Stainless Steel Tie Straps 4 pack

14"

2002SS

Matrix Heatshield Mat • All of the features of the Matrix HeatshieldWrap in a self adhesive sheet • .008”thick rolls are 12”x 24”overall • Outperforms the competitors foil stickers by up to 60% • Use on fuel tanks to prevent fuel from boiling • Use on intakes and air boxes to reduce incoming air temperatures • Perfect for use under fairings to prevent melting • Reduces up to 80% of radiant heat • Can withstand 1200 degrees continuous and 1800 degrees intermittent • Adhesive sticks to most clean surfaces and cuts easily with scissors High Temperature Exhaust Wrap • Made from high quality fiberglass yarn, contains no asbestos • Withstands 1200 degrees continuous and 2000 degrees intermittent • Reduces radiant heat by up to 50% • Available in black and tan finish • Increases horsepower and improves rider comfort • Complete kits include (4) 14”stainless steel ties and detailed instructions Description Size Matrix Mat 12" x 24"

Matrix 1224MM

1224MM

Description 2" Complete Kit 1" Complete Kit

Size

Black P/N Tan P/N

2" x 25' 1" x 50' 2" x 25' 1" x 50'

2002BK 2001BK 2002BB 2001BB 2002SS

2002TA 2001TA 2002BT 2001BT

2" Wrap only 1" Wrap only

2002BK

www.accel-motorcycle.com Stailess Steel Tie Straps 4 pack

14"

* All ACCEL exhaust wrap is made in the USA

25

MR. GASKET PARTS

Fast Fill Funnels • Plastic funnels with a built in brass screen filter • Available in 2 sizes

Description

P/N 3695 3697

3697

Large 6 qt funnel Small 2 qt funnel

3695

Lead Free Wheel Weights • Fits any mag or spoked wheel • Installs easily with no tools • Lead free and non toxic

Description

P/N

1428LF

1 lb pack with (4) 4" strips

1428LF 3650GLF

Bulk 5 lb box

Bulk Gasket Material • ACCEL is proud to offer premium quality Mr. Gasket gasket material • Great for making hard to find or obsolete gaskets • Also works great in custom applications

Description

P/N

9612

Fiber Gasket Material, oil applications 1/64" x 9" x 36"

9610 9611

1/32" x 9" x 36"

Cork Gasket Material, oil applications 1/16" x 12" x 36"

9612 9613

9614

1/8" x 12" x 36"

Compressed Gasket Material, oil fuel and coolant applications 1/32" x 12" x 18"

9614 9615

1/16" x 12" x 18"

Exhaust Gasket Material rated to 1200 degrees 10" x 10" Performance Material

77

6" x 24" Performance Material 10" x 10" Ultra Seal steel core 6" x 24" Ultra Seal steel core

77A

77

5960 5961

Intake Gasket Material

12" x 12" 6" x 24"

77B 77C

77B

26

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MR. GASKET PARTS Aluminum Vise Jaws • Aluminum soft jaws work great in any 4”-6”steel vise • 6 strong magnets hold jaws securely to vise • Black anodized billet aluminum construction • V shaped cutouts hold and protect round or hex shaped parts • Perfect for securely holding engine and suspension components

Description

P/N

AluminumVise Jaws

V304

V304

Safety Wire Pliers and Lock Wire • Wire cutter, wire twister, and heavy duty pliers in one tool • Lock wire is made from .032”stainless steel

Description

P/N

SafetyWire Pliers Safety LockWire

8023G 8022G

8022G

8023G

Engine Port and Polish Kit • Allows detailed porting, polishing, and flash removal • Ideal for use with cast iron and aluminum engine parts

• Includes (1) tapered cutting stone, (1) 1”mini grind flex-flat wheel • (29) assorted polishing rolls and (3) various length mandrels

Description

P/N 4362

Port and Polish Kit

4362

www.accel-motorcycle.com

27

ACCESSORIES

Wire and Hose Sleeving Kits • A great way to clean up the look of loose wires • UV resistant braided sleeving available in 5 colors • Protects against abrasion and is resistant to gasoline, oil and most chemicals • Kit includes 10’of 1/4”, 10’of 3/8”, and 5’of 1/2”sleeving plus heat shrink tubing to finish it off

Color Black

Description Sleeving Kit Sleeving Kit Sleeving Kit Sleeving Kit Sleeving Kit

P/N

2007BK 2007BL 2007CR 2007CH 2007RD

Blue

Carbon Chrome

2007CR

Red

Engine Cleaning Brush Kit • Kit of 9 assorted stiff bristle nylon brushes

• Will not melt or soften when used with cleaning solvents • Handles are made from heavy gauge twisted steel wire • Loops on each handle for easy hanging and storage

Description

P/N

Engine Cleaning Brush Kit-Includes 9 brushes

5192M

5192M

Spark Plug Indexing Tool • Designed for performance engine builders looking for every ounce of horsepower • Allows for specific location of the ground electrode for maximum flame front generation

• Works with both flat and taper seat 14mm spark plugs • Billet aluminum construction with a gold anodized finish • Knurled flats allow for hand held use or can be secured in a vise • 30 packs of indexing washer avaialable seperately

Description

P/N

14MM Spark Plug Indexer

1005M 1002M

14MM IndexingWasher Kit-30 assortedWashers

1005M

28

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PROMO ITEMS

ACCEL Motorcycle Products Welcome Mat • ACCEL logo floor mat for your garage, shop, or home • Measures 34”x 57”

Description

P/N

Industrial grade rubber backed floor mat

74459G

74459G

Logo Decals • Silk screened vinyl decals • Self adhesive decals stick to any clean dry surface

Description

P/N

ACCEL Logo Small 1-5/8" x 4" ACCEL Logo Large 3-3/4" x 9-1/2"

M23956 M23957

M23957

Custom Counter Stool • Premium quality diner style stool measures 28.5”tall with a 14.25”cushion • Padded seat features the famous yellow ACCEL logo • Durable steel frame is triple chrome plated for good looks • Easy to assemble with simple hand tools

Description

P/N

ACCEL Counter Stool

74348G

74348G

ACCEL Performance Banner • Great for the race track, garage wall or basement • Heavy gauge vinyl with brass eyelets for easy hanging • Measures 2’x 4’

Description

P/N

Performance Banner

74384G

74384G

technical service 216-658-6429

29

TROUBLE SHOOTING

Trouble Shooting Guide-Charging Systems

CHECK THE STATOR: 1. Disconnect the regulator from the stator at the terminal inside the crankcase.

2. Check for continuity between either stator pin and the crankcase. Continuity indicates that the stator is grounded and needs to be replaced. 3. Check the resistance between the stator pins. A reading of 0.1 to 0.2 ohms should be present. A lower reading requires that the stator be replaced. CHECK THE OUTPUT: 1. Again disconnect the regulator, and connect a voltmeter set to AC volts across the stator terminals. With the engine running at 2000 rpm, that should be a reading of 32-40 AC volts. The output will increase or decrease 16-20 AC volts for every 1000 rpm. CHECK THE CURRENT DRAW: 1. With all accessories, ignition, and headlamp high beam turned on, read the current draw. 2. The current draw should be at least 3.5 Amps lower than the output listed in the SPECIFICATIONS section of the Harley-Davidson service manual. You may have too many accessories drawing power for the system to handle. 3. Have the Battery Load Tested. HOW DO I POLARIZE MY GENERATOR? 1. A generator that is not polarized will burn relay points, cause a dead battery, or damage to the generator. 2. Momentarily touch a jumper wire between the BAT and GEN terminals on the generator.

Test Procedure for Unilite ® & E-Spark ® for Motorcycles

With the Module wired to the coil like it’s ready to run. Take the cap off and position the Module so you can see it. Turn the key on, test voltage on the negative side of the coil, which is where the green wire attaches to the coil. To do this the Red lead from the voltmeter will go to the Green wire on the coil. The Black wire from the voltmeter will go to ground. Set the voltmeter for 12 volts DC. With the ignition switch ON you should have about 12 volts. Then take a card or match book and place it in slot of the module to block the photo optics of the module (see pictures). The voltage should drop to 1-2 volts. Remember it’s an infrared LED you won’t see it. If the test results are as follows the Module will need to be replaced: (a) Voltage does not drop to 1-2 volts when optics blocked. (b) Voltage always stays below 2 volts, blocked or not. (c) Voltage only drops above 2 volts, the higher above 2 volts the weaker the spark.

Possible causes are: • Faulty charging system: stuck or shorted regulator, bad ground, dead cell or defective battery, defective stator or generator. • Faulty ignition switch, direct shorts in electrical system. • Faulty starting system: starter drag. • Trying to start motor with battery charger hooked up. • Non-suppression spark plug wires (copper or stainless solid core wires). Spark plug wires must be Spiral Core or Graphite Core suppression wire. • Welding on the Bike with Module still hooked up (unplug the white connector to the Module before welding). • Improper coil, use 2-4 ohm coil (check installation instruction). If you must replace the Module, replace it with Mallory Part #A605. If after completing the test you still have questions 216-658-6429.

30

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