Last update Aug. 5/22
Basic components of single ECU EM-5 6F aircraft EFI system for Lycoming 540. No wiring shown here.
Ron Gawer's SDS equipped 540 on the dyno at Ly-Con. Sports SDS Aero billet flywheel and billet valve covers.
Please be aware that there are numerous variations among Lycoming engines themselves and clones versions as well. Some parts may not fit or may have to be modified in certain cases.
To place your order, it's best to email or phone us to discuss your project as each system is custom made and tailored for each client. We'll get a list of all your details, discuss wiring lengths, colors, options etc. and then quote you. You then pay by Visa or Mastercard, wire transfer or E-transfer for Canadian customers.
Six cylinder fuel and spark control, single ECU, twin coil packs, dual pump module, throttle body, injectors, regulator etc.- 18 pounds- $6192US
Six cylinder fuel and spark control, dual ECU, twin coil packs, dual pump module, throttle body, injectors, regulator etc.- 20 pounds- $7428US
These prices don't include options listed below
Weights above include all wiring and sensors. Does not include spark plugs or plug wires. Weights can vary with harness lengths and coil mount choices. Prices are approximate for parallel valve engines and can vary with options ordered. Angle valve systems are slightly more expensive. Please email us for an exact quote- E-mail:firstname.lastname@example.org
Individual cylinder fuel trim $300
PC data logging $110
Digital fuel flow output to engine monitor $100 (eliminates Red Cube mechanical flow transducers)
To place your order, it's best to email or phone us to discuss your project as each system is custom made and tailored for each client. We'll get a list of all your details, discuss wiring lengths etc. and then quote you. You then pay by Visa or Mastercard, wire transfer, E-transfer for Canadian customers.
When replacing legacy mechanical injection, carbs or mags with EFI/EI, you may want to delete items no longer required. Thunderbolt and certain engine builders will delete these items and take them off the price of a new build. Below is a list of parts not required when fitting SDS EFI:
1. Mags, ignition harness, spark plugs
2. Servo, flow divider, lines, injectors
4. Fuel pump and pushrod
5. Flywheel. (Note that new Lycoming flywheels may lack the 12 tooling holes which we use to mount the magnet drilling block to).
Please note: our magnet mounting system for Lycoming engines is not compatible with the Sky Dynamics lightweight flywheels, new Lycoming flywheels lacking the 12 tooling holes around the periphery or factory dual pulley groove flywheels. We do have a solution for Airflow Systems aftermarket flywheels for driving a/c compressors and a special drilling jig for these.
Magnets installed in AFS flywheel for use with their air conditioning system on RV-10s.
Havoc Racing's twin turbo Lycoming with SDS EM-5
Mike Robinson's 540 Rocket
Hot start video on Mike's Rocket
Steve Murray's very clean IO-540 installation
Les Kearney's RV-10
Video flying SDS EFI in Les Kearney's RV-10
Lean of Peak video
Les Kearney's Aero Sport IO-540 with dual SDS EFI EM-5 and SDS Aero billet valve covers
SDS 80mm throttle body on Barrett cold air intake
Crank sensor mount detail
SDS lightweight billet flywheel
Rear coil mount and backup alternator detail
https://rv10.ca/ Resource for RV-10 specific information- building, SDS EFI.
Ashley Miller was kind enough to bring the following to our attention; It seems new Lycoming Thunderbolt engines may come with flywheels which lack the tooling holes to locate our magnet drilling jig. In these cases, you'd have to obtain an older flywheel or get one of our SDS billet ones.
Gaylon Koenning's beautiful RV10 is flying with the dual SDS EFI system in Texas. 550 flight hours to date.
New boss/ injector combo for Reno 2019. 1/4NPT boss fits AV engines. Supports 660hp on 360/390 engines and 1000hp on 540/580 engines.
Standard boss for parallel valve Lycoming engines mounts EFI injector in original injector hole. Uses an injector with a stainless steel body for low heat transfer, proprietary high strength- low heat transfer, alloy steel, lower spigot, 7075-T6 retainer ring, stainless cap screws. Threaded adapters have 4 times the tensile and yield strength and many times the fatigue resistance of our competitor's 7075-T6 bodies at 400F. No more welding bosses to induction tubes. Please note, these parts are only sold with complete SDS system orders.
Center mount fuel block for 6 cylinder Lycoming engines
Block mounts through these case bolt holes
Shown with -3 stainless braided lines connected
Dual fuel pump module mounted in an RV10
Dual root mount filter setup from Flightlines
Video of Bill Beaton's supercharged IO-540 Rocket running SDS EM-5 and CPI
Bill Beaton's IO-540 on the test stand at Aerosport
Bill's Supercharged Rocket. World's fastest Rocket- 282 mph at Reno 2016
SDS EM-5 in Bill's Supercharged Rocket
540 top coil mount
Dual Mag cover solution plugs mag hole and mount one coil pack.
For Dualmag Lycomings, we have a special cover plate and spigot to plug the mag and oiling holes. Note that not all engines have the mag oiling hole. Ones that don't, can use our regular cover plate and coil bracket to mount one coil there as shown above. There are 3 different shaft sizes for the spigot, please measure yours before ordering.
Lycoming IO-540 Dual System
The 3 photos below show the components of our complete dual Lycoming IO-540. This particular system is destined for a an overseas customer's TIO-540 project.
Main ignition components
Main fuel components, weld-in bosses shown here. Most engines can now be fitted with our screw in bosses
Tefzel wiring harnesses
Dual coil mount for RV10 aircraft. This mounts to the top of the engine mount. Comes with mounting hardware.
Many thanks to Ashley Miller for the design and these photos
To show our appreciation for the continuing support from our customers, we'll be offering free EM-6 ECU upgrades when they are available later this year to all customers who purchased a complete aviation EM-5 system in 2018-2022. For customers who have purchased a complete aviation kit (EM-5 ECUs only) prior to 2018 (including rebranded EFXX ones), we'll be offering new EM-6 ECUs at a special discounted price. The EM-6 will be the next generation SDS ECU, based on the continuing evolution of EM-1 through EM-5 ECUs going back to 1994. We hope to be done testing in the 4th quarter of 2022.
Standard and Optional Features
SDS offers the following features not found on other vendor kits:
The new programmers feature a higher temperature spec LCD (-20 to +70C) and adjustable contrast and brightness control. The brightness control was added per customer requests for night flying comfort.
Here we see the contrast control screen- 16 settings
This shows the old defaut level brightness
This is a medium level brightness
This is a low level setting and the 0 setting is a bit lower than this.
Fuel pressure regulator mounting
Magneto cover. Install without gasket, just use RTV.
Hall sensor mount and dual Hall sensor in place
Weld-in bosses for race applications and engines without the 1/8 NPT injector holes in the heads
Photos of 3.50 inch bolt spacing Hall mount
3.25 inch bolt spacing Hall mount. Note mounts have threaded holes to bolt cable protection hardware to.
Please check the center to center front crankcase bolt distance. Some measure 3.25 inches, others 3.50 inches. We need to know this to send you the correct Hall sensor mount.
Billet 80mm throttle body to replace Bendix RSA-10 and AFP FM-300 servos when converting to EFI. Horizontal mounting.
Air horn accepts 3.5 inch SCAT hose, 3.5 inch ID K&N filters or 3.5 inch ID Silicone hose couplers. 6061T6 construction, stainless steel shaft riding on sealed roller bearings, 7075T6 throttle arm, brass butterfly, accepts OEM Bosch TPS, O-ring sealed air horn to body and flange to sump. Under 2 pounds and only 3.625 inches high. Integral throttle stop. Stainless hardware.
Rear coil pack mount for 540 engines
Spark plugs and adapters for long reach Angle Valve Lycomings (IO-390/ 580)
MSD Plug Wires and Boots
Be sure you push the plug and coil boots all the way down to engage the terminals fully. There should be about a 1/8 inch gap as shown in the photo below
Magneto Parts to Remove on 6 Cylinder Lycoming Engines
Exploded view of magneto parts on Lycoming 540 engines: 540magparts.pdf
When replacing the mags on 6 cylinder Lycoming engines, be sure to remove the gear/ cup (6), cush drive (2) and pilot bearing (7) as shown above. Be very careful not to drop any of the parts into the sump! The extension housing (4) may be removed or left in place as desired
Ly-Con Rebuilding Co.
8231 W. Doe Ave.
Visalia, CA 93291
(559) 651-3212 Fax
Website: www.lycon.com Lycoming EFI