You may have seen my earlier post for a complete electronic ignition system for $99.

Now, the same system can be built for $63 by using a Mallory 6100M infrare
The Mallory unit ($34.16 from Amazon.com) uses an infrared beam interrupted by a rotating "shutter" in place of the points cam. This module is self contained (n
replacement for the points cam from the shank of a bolt and drill a couple of holes in the lid from a jar of Gerber's Baby food for the shutter. Attach the lid from th

Parts List for Gerber Mallory Pointless Ignition

Mallory 6100M $34.16 @ Amazon.com (FREE Shipping!)
Mikes XS Dual output coil #17-6803 $28.00
Bolt, X 2 in. ( You Already got one)
Jar Gerbers Baby Food, small glass $0.69
Misc wire, connectors $0.49
Total $63.34

A drawing of the mandrel that fits on the advance rod after you have sawed off the threads on the points side. This is really the only part that has to be fabricated. E
workbench when I started the project. The 1.05 dimension is critical, as is the location of the thru hole for the roll pin, because of the final clearance of the Gerber

Here is a drawing of the relative position of the slots in the lid, mandrel and Accel Infrared sensor. The roll pin lines up with the leading edge of the slots and the li
firing zone before drilling the offset hole in the lid, then fine tune with a strobe with the engine running.

pamcopete
Guest

May 9, 2007 at 2:48pm

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The ballast resistor is not required for coils with a 2.5 Ohm or greater primary resistance and Mallory has just introduces their
Accel 2005 module. These changes result in a lower cost of parts.

pamcopete
Guest

May 13, 2007 at 7:41pm

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Additional notes:
To begin with..

..this mod requires that you remove the spark plug clearance "bulge" in both the points housing and the poin

hack saw off the threads on the points end of the advance rod..
mandrel...

.....and..... you have to drill out the hole for the locating

..I think that about four people just left the room...oh well...progress has it's price!!

Drill and tap two holes to mount the Accel or Mallory module on the points plate as shown. Only one points plate advance lock

essential
that the metal heat sink on the bottom of the module make perfect, flat contact with the points plate!! Use heat sin
part of the label under the module....don't know why they put it there.

The slots on the Gerber Lid are started with two 1/8 th in. holes exactly 180 deg apart. Using a rat tail file, these holes are then
in a 50% duty cycle of on time vs off time. Clean out the plastic coating that is inside the lid and spray paint it absolutely flat b
false triggering.

Initial timing is established by positioning the crank on the "F" timing mark and rotating the lid on the center screw hole count
infrared "eye" of the module. (see diagram above). Mark and drill the offset hole at this point. This establishes "initial timing"
line up the roll pin with the slot as shown, that will also establish the initial timing.

Using a timing light, loosen the screw holding the points plate and rotate the plate and module to obtain proper timing at 1,200

If you shine the timing light on the Gerber lid, you can see if both leading edges, as viewed on the top, of the two slots are exac
advanced than the other. It's one of those things that you have to see to fully understand. This "rat tail file" timing adjustment o
start over.
After doing the "rat tail file" timing adjustment, redo the basic timing by rotating the points plate as before.

The Mallory or Accel comes with wiring instructions. Brown wire to ground.....Red wire to +12 from the kill switch and green

You must use suppressor type spark plug wires and resistor spark plugs . You will have to use 5/8ths resistor plugs for clearanc
to be the Bosh FR8DCX (7557).
Here is a list of reccomended spark plugs:

xs650temp.proboards29.com/index.cgi?board=ID&action=display&thread=1163124662&page=1#11

The output voltage from the coil will depend on which coil you choose. Some of the "flame thrower" coils advertise up to 80,0
the coil has a primary resistance of at least 2.5 ohms, you can use any dual output coil that you want.
Hopefully, these notes will give you a better insight as to how to get this mod going.

pamcopete
Guest

May 30, 2007 at 2:16pm

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Here is a PIC of the system with the lid removed:

pamcopete
Guest

Jun 19, 2007 at 8:26am

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Here is a pic of the HD OEM 31609-80 (after market 17131) coil mounted in that little corner at the front where the frame com

shifty
Crew Chief

Jul 6, 2007 at 7:23pm

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hmmm seems 'almost' simple enuff. I'd want a spare advance rod and I think I have a handle on some extra parts near by .. che
78 XS650 Special, 79 XS650 Special,
07 V-Star 1300
Posts: 686

I don't understand the 1/8" holes in the cover.

I do understand that they have to be exactly 180 apart. I thought they would
infrared sensor fire the plugs from the leading edge of the rounded hole? Is that why the mandrel has to be exact length of 1.05
edge rounded hole ... insignificant?
Or .... am I waaaay off in left field? Just trying to understand it.

pamcopete
Guest

Jul 6, 2007 at 7:50pm

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shifty

Yes, the Mallory module fires the coil on the leading edge of the slot. The non slotted sections of the lid represent the Dwell an
provide exact alignment for the slots in the lid and the infrared sensor / source on the module and to provide clearance between

holes are on the rim of the lid and provide a starting point for the rat tail file. You are correct, a square edge would be better as
slightly in and out. I actually put a thin shim washer on the advance weights side to limit this movement.

If you do not want to saw off the threads on your advance rod (yeah, I cringed when I did it) then, of course, just drill the cente
problem with that is, ensuring that the lid is absolutely centered on the mandrel. But, if you have the patience, then by all mean
prunes?)

shifty
Crew Chief

Jul 6, 2007 at 8:33pm

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Thanks ... that is clear, but now ...

78 XS650 Special, 79 XS650 Special,
07 V-Star 1300
Posts: 686

hmmm ... I never did understand nor care what dwell angle was, until now. Reading the following: www.moyermarine.co

Dwell angle is a measure of the duration of time that the primary circuit of the ignition system is closed to energize the primar
distributor rotor, hence the use of the term "angle". In actual operation, as the distributor mechanism rotates, the points (or ele
degrees of rotation, and open between these points. Simply as a matter of interest, this means that the total number of degrees d
open, will equal 360 degrees.

So my question is ... if the dwell angle is 90 degrees (no slot opening) ... the slot opening must also be 90 degrees (both multip
Does the length of the slot matter? Seems to, in, I'm sure, my above misguided logic!

pamcopete
Guest

Jul 6, 2007 at 8:51pm

Quote

shifty
Right again! Each slot is 90 deg, so each non slotted area is also 90 deg. This means that the coil is on for 50% of the time. The
cycle (90 deg dwell) is a good compromise. A longer dwell is important for RPM's at or above 7,000 RPM because the actual t
angle to, like 100 deg and benefit from a hotter spark at high RPM's but a shorter coil life. In other words, although the dwell a
speed increases, so the coil has less time to fully charge before discharging, resulting in a weaker spark. Fully electronic system
higher speeds, more dwell angle. The Mallory module is not that sophisticated, nor does it have to be for this application.

With this system, you could actually have different lids with different dwell angles for different circumstances. Just two screws

shifty
Crew Chief

Jul 6, 2007 at 9:35pm

Quote

I like to learn something each day ... mission accomplished ... thanks pcpete. Great stuff.
78 XS650 Special, 79 XS650 Special,
07 V-Star 1300
Posts: 686

pops
Crew Chief

Jul 16, 2007 at 6:03am

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I see Gerber just recalled their rice and oatmeal. I hope none of you used any lids from these bad batches. ;D
pops

If it aint broke, I aint worked on it yet

Posts: 1,008

mashermoto
Senior Member

'72 XS2 (Lucille)

'79 SF (popsycle)
'nuther '79 SF (freebie)

Jul 16, 2007 at 6:16am

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Pops, I'm using the prunes...it slides on easier ;D

Posts: 487

My hero's have always been flat trackers.

pamcopete
Guest

Jul 16, 2007 at 7:07am

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Well, the 650 IS a "Rice Burner"! ;D

pamcopete
Guest

Jan 8, 2008 at 8:43am