Assembly Instructions for 2V-Boxer Hall - Sensor

E_B_PB_5F_08 7. Version (c)Sep.2005

Parts List: Ignition box

Pickup with 2 screws
Rotor with 6 washers
Cable binder
Ignition coil
Ignition cable

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The Power Block ignition system is far superior to conventional ignitions that usually achieve double the ignition tension, double the
ignition energy, as well as double the spark duration. The adjustment of the ignition timing is worked out by a digital High Speed
Microprocessor, with 16bit resoloution (65536 points) for each single revolution. The Signal conditioning as well as the ignition amps
control are also carried out digitally, to achieve maximum efficiency with a minimum loss. The necessary D-Well time of the ignition
coils is worked out digitally to achieve maximum energy saving. The output requirements of the ignition system (module + ignition
coil) is approximately 17W with 1000 RPM and approximately 67W with 5000 RPM.

The full performance of our Power Block ignitions is only possible with SILENT HEKTIK ignition coils, because
the ignition curves for the relevant ignition energy as well as tensions are tuned and the D-Well timing on the
technical details of the coils are cut.
With unsuitable or inadequate ignition coils, not only does the gaurantee expire , there will also be bad trottle
responce; bad coldstart or perhaps missfire:

SAFETY PRECAUTIONS AND NOTICES

Caution High Tension! Danger ! Mortal danger !
To avoid injury or destruction of the electronic, attention should be paid to the following when
working on vehichles with full electronic digital high energy ignition systems:
- Read the assembly instructions carefully and completely and follow the instructions.
Display warning labels in a good visible place!
- To install the modules, specialized knowledge and tools are required.
- People with a Pacemaker should not carry out work on electronic ignition systems.
- To synchronize the carburettor never pull out a spark plug.
- Do not touch or remove ignition cable when the ignition is on.
- Only connect of disconnect the cable from the ignition system when the ignition is
turned off.
- Always connect the high tension cable to ground (mass) with or without the spark plugs
after removal.
- Checking the function of the high tension part with a spark to the ground (mass) leads
to damage.
- Washing the engine or vehichle is only to be carried out when the ignition is turned off
and the engine is stopped.
- The ignition module should be carefully protected from static tension.
- Seperate ignition module from the cable harness when electric welding.
- Faulty alternator regulators (max. tension 15V ) are often the cause of breakdown.
- Jumpstarting with a battery charger is only permitted for 1 minute with max. 15V.
- There is no gaurantee for the accuracy of the timing curves with tuned engines;
consultation and tuning of the tuner absolutely necessary.
- Gaurantee-, replacement or claim for compensation only in reference to the supplied
electronic; mistakes and changes in future to be accepted.

MonoCoil 1.7 120mJ 42kV DualCoil 1.7 120mJ 42kV

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ASSEMBLY OF THE PICKUPS AND THE ROTORS:
The assembly of the ignition rotors is carried out directly on the dynamo-rotor. Use the
original screws without the spring washer. Please check the rotor’s seating areas and
remove any possible calibration that can result from the spring washer. The pickup is
fastened to the Bosch-dynamo with the original U.V.W.plug’s screws. On the SAPRISA-
dynamo an original screw with a 5mm distance-sleeve is used; for others a M5 thread
must be installed for the second fastening on the dynamo.
The distance of the rotors to the pickup should be 0,5mm - 0,7mm on all trigger-noses.
The mechanical basic adjustment refers to the static ignition timing:

Tourer + Sportler 6° BTDC Sportler up 1:11 8° BTDC

Twinspark till 1:10 6° BTDC Twinspark up 1:11 7° BTDC
Hall pickup on the Bosch alternator
For the basic adjustment, use the right cylinder and the corresponding ignition rotor
nose, as in the right photo.
The left over edge of the rotor should stand in the middle of the pickup centre. The
trigger-rotor turns clockwise.
To hold the ignition rotor when tightening, use the tool of a Flex and a screwdriver on
the sprocket of the clutch.
Check the static ignition timing with a timing-light at approximately 1200 RPM.
You don’t need to adjust the left cylinder.

ASSEMBLY OF THE IGNITION BOX AND IGNITION COILS:

The assembly of the Power ignition box is most successful in a protected place, like
under the tank or under the saddle. Our digital ignition box can be fastened with rubber
rings to the frame tube or with the backside of the M4 threads on an aluminium plate.
static position of the trigger system
The cable exit of the box should always be dry.
The ignition coils are assembled in place of the original ignition coils. Depending on
suitable mounting. To avoid faults, take care when laying the cable that the biggest
possible distance is from the Pickup cable to the ignition cable. The engine housing must
have a good ground (mass) connection to the battery -> Battery ground (mass) cable on
gearbox housing.
With an optimal working ignition system the amount of the spark plug gap is 0.6 -
0.8mm. Please use radio surpressed ignition coil connectors with a minimum resistance
of 5KOhm or a resistance cable. The operation of this device will only be perfect with a
good radio surpression ( also for alternator-regulator), especially with old contact-
regulators.
Protect all connectors form damp and humidity with a special grease. Never use battery
Pole grease, because it is alkaline. Soldered crimp connectors lead to hairline cracks PowerCoil on the /5 frame
and breakdown. Faulty Kill switches on the handlebars and the sidestand are often a The ignition-box can be mounted on the other side
source of trouble.
Only ignition coils with a primary resistance of minimum 3Ohm should be used ->
Gauranteed loss when not used!!! When the engine is stopped the amps power of the
ignition module will be switched off after a few seconds. Careful when carrying out
maintenance work.
Older electronic rev counters should be connected to the grey exit of the box. Newer rev
counters can be connected to the ignition coil clamp KL1. Our box will not be damaged
from trying out.

ADJUSTMENT:
For basic maintenance of all single-spark ignitions (normal ignitions) the 34° curves
come into consideration:
Basic - ignition Nr. B ( one timingcurve )
The distance from the box to coils should be min. 10cm
all Tourer Nr. 9 all Sportler Nr. 8
On ignition-knocking because of bad petrol or with side car combination (overload), use
the next flatter timing-curve form.
To adjust a twin-spark ignition, a lot of experience & feeling for it is necessary . It is
better if you stick with the tuners instructions. With independent ajusting use the
following adjustments first of all and try the next timing-curves in driving:
all Tourer till 1:10 6° Nr. 3 alle Tourer up 1:11 4° Nr. 5
all Sportler till 1:10 6° Nr. 2 alle Sportler up 1:11 7° Nr. 1
With maximum driveability and the smoothest engine run the setup is complete. With
compression-ratio over 1:10 you should use radio compressed spark plugs.

Two PowerCoils for TwinSpark

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 Connection diagram for single-spark :

TwinCoil

rev counter for camshaft speed = on gray cable rev counter for crankshaft speed = on coil minus
Basic - ignition without a switch : 6°BTDC stat. controll with a timing-light = at 1200 RPM
On the TEC ignition-coils the plus is black.

Connection diagram for twin-spark :

TwinCoil

TwinCoil

BLAU = blue ROT = red GRÜN = green SCHWARZ = black LINKS = left RECHTS = right

IGNITION TIMING RANGES AND BOX - DIAGNOSIS:

By undoing the four screws on the bearer angle, the top cover can be removed.

The switch for the ignition lines, range 0 to 15, is inside the box.
Take the appropriate timing-curve from the diagramms.

There is also a diagnosis interface in the form of a light diode:

Ignition off = LED off

Ignition on = LED blinks to the switch position
Start with > 7V = LED blinks at half engine speed
Start with < 7V = LED don´t lights at BTDC
Start with > 120 RPM = LED blinks at half engine speed
Start with < 120 RPM = LED blinks to switch position

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Die 16 Zündkurven der PowerBlock - Zündung ab Version PB_34 Schalterstellungen:

7° vOT statisch
—————————–

Nr. F 42° L
Nr. E 40° S
Nr. D 38° L
Nr. C 37° S

8700 U/min max.

TwinCoil D-Well
mit Standgas Stabilisierung

7° vOT statisch
—————————–

Nr. B 36° L
Nr. A 35° S
Nr. 9 34° L
Nr. 8 33° S

7600 U/min max.

TwinCoil D-Well
mit Standgas Stabilisierung

7° vOT statisch
—————————–

Nr. 7 32° L
Nr. 6 31° S
Nr. 5 30° L
Nr. 4 29° S

8700 U/min max.

TwinCoil D-Well

ohne Standgas Stabilisierung

Twinspark bei 4° vOT

7° vOT statisch
—————————–

Nr. 3 28° L
Nr. 2 27° S
Nr. 1 26° L
Nr. 0 25° S

7600 U/min max.

TwinCoil D-Well
mit Standgas Stabilisierung

Twinspark

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 A DRESSE : S ILENT H EKTIK
: H ANSASTR . 72 B
: D-59425 U NNA
: G ERMANY
T EL -N UMBER : +49-2303-257070
F AX -N UMBER : +49-2303-257071
H OMEPAGE : WWW .S ILENT -H EKTIK . COM

S HIPPING : W ORLDWIDE

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