MSD Watercraft Ignition System
Contents
1. MSD Watercraft Ignition System PN 4242 4243 4244 IMPORTANT Read these Instructions before attempting the installation WARNING During installation disconnect the battery cables When disconnecting the battery always remove the Negative cable first and install it last Parts Included In This Kit 1 MSD Watercraft Ignition PN 4272 1 Ignition Coil PN 4292 1 Ignition Wire Set MSD Super Conductor PN 31009 1 Trigger Pickup PN 4316 1 Trigger Plate Kaw 650 750 PN 4312 Yam 650 701 760 PN 4311 Sea Doo 720 PN 4328 1 Flywheel Kaw 650 750 PN 4302 Yam 650 701 760 PN 4303 Sea Doo 720 PN 4304 1 Shim Kit 2 020 Shims 1 060 Shim PN 4318 1 Grommet Kaw 650 750 PN 4321 Yam 650 701 760 PN 4322 1 18 ga Violet Wire 6 Perma Seal Ring Lug Terminals 3 No 6 2 No 10 3 5 16 8 Perma Seal Butt Connectors 18 22 Ga 2 4 40 3 8 Phillips Screws 2 4 40 1 2 Phillips Screws 1 3mm x 5mm Woodruff Key Kaw 650 750 Models Only 1 3mm x 3 6mm Woodruff Key Sea Doo Only 1 5mm x 6 5mm Woodruff Key Yam 650 701 760 Models Only 2 6mm x 20mm Button Head Stainless Bolts Kaw 650 750 amp Yam 650 701 760 Models Only 2 14x 6 4mm Compression Washer Kaw 650 750 amp Yam 650 701 760 Models Only Parts Not Included But May Be Required a Ignition Mounting Plates lo Sena maey WOE Pee Kawasaki 750 SX SXi PN 4395 1 Waterproof On Off Switch MSD PN 4370 Yamaha S Jet Blaster VXR 12. FAX 915 858 9241 CHECKING THE AIR GAP It is important to have the correct air gap between the pickup and the flywheel Too much may not trigger the ignition while too little may cause contact to the pickup 1 2 Remove the flywheel and measure the INSTALLATION INSTRUCTIONS Position a small amount of clay on the top of the trigger pickup Figure 11 Place the flywheel on the crankshaft and lightly tap with a rubber or wooden object to hold it in place thickness of the clay Refer to the chart Figure 12 for the number of shims that will need to be placed under the trigger pickup to obtain the correct air gap between the trigger pickup and the magnet in the flywheel The correct air gap is 050 to 094 Insert the necessary shims under the trigger pickup Make sure the trigger retaining bolts are the correct length for the number of shims being used and are tightened firmly INSTALLING THE FLYWHEEL Heating the flywheel in boiling water to evenly expand the flywheel material before it is installed is necessary in the following procedure Be sure to wear adequate skin and eye protection to prevent possible burning FLYWHEEL FLYWHEEL COVER DIAL CALIPER 11111111111111111111111111111111111111111111111111 CLAY gt SPECIFICATION 0 050 0 094 Figure 11 Checking the Air Gap Note On Kawasaki 750
3. Screw the supplied bolts and compression washers into the case and lightly tighten to hold the trigger plate in the center of the case s mounting pads Kawasaki 750 installation The engine case mounting pads of the Kawasaki 750 must be drilled and tapped Figure 10 A Drill and tap a hole on each pad 2 165 from the center of the case Drill and tap each hole fora 6mm x 1mm allen head bolt using a No 9 or 5mm drill bit and a 6mm x 1mm tap Each hole needs to be drilled 21mm deep Figure 8 Assembling the Trigger Plate B Rotate the plate through the slotted positions to ensure that the plate slides smoothly and does not rock If resistance is felt remove the trigger plate and inspect the mounting bosses for burrs and file flat if necessary Note The PN 4312 Kawasaki 650 750 Trigger Plate outside diameter is machined to fit the mounting pads on the Kawasaki 750 engine When this plate is used on a Kawasaki 650 engine the trigger plate will have approximately 1 16 play on each side Figure 9 Mounting the Trigger Plate Assembly 2 Slide the Green trigger pickup wires through the grommet Install the grommet with wires attached in the case and secure in place using the stock mounting hardware Place a small amount of silicone sealer around the wires where they enter the grommet Figure 10 Modifying the Kawasaki 750 Case MSD IGNITION 12120 ESTHER LAMA SUITE 114 EL PASO TEXAS 79936 915 857 5200
4. 43731 GRounD PN 4390 O STARTER START STOP SWITCH Figure 15 Wiring the MSD Watercraft Ignition System MSD IGNITION 12120 ESTHER LAMA SUITE 114 EL PASO TEXAS 79936 915 857 5200 FAX 915 858 9241 8 INSTALLATION INSTRUCTIONS Note It does not matter which Green wire on the ignition is hooked to which Green wire on the trigger pickup CONNECTING THE FACTORY STOP SWITCH PN 4272 To retain use of the factory stop switch located on the handle bar attach the two wires coming from the stop switch to the two GREEN wires from the MSD Ignition Figure 15 Note Sea Doo uses factory Landyard Switch to kill the engine See Lanyard Switch hookup below CONNECTING THE IGNITION KILL LANYARD FEATURE Landyard Switches are listed as Normally Open or Closed when the switch is not connected to anything and the Landyard is removed from the switch Normally Open Lanyard Switch Connect the Violet wire of the MSD Ignition to one side of the N O Lanyard Switch and the other side to positive battery 12 volts Figure 16 BATTERY PN 43731 LANDYARD SWITCH Figure 16 Normally Open Lanyard Switch CONNECTING THE HOLESHOT FEATURE Connect the WHITE wire to one side of a normally open momentary switch and the other side of the switch to the BLACK wire Figure 17 PN 4372 HOLESHOT SWITCH Figure 17 Connecting the Holeshot Feature with a Normaly Open Switch CONNECTING A TACHOMETER The tach signal from the
5. MSD is a 12 volt square wave signal so many types of tachometers can be used with the ignition Some of the more commonly used tachometers are the Jetmeter Water Strike Marine Optak J R Electronics VDO Faria and Autometer Connect the tachometer trigger wire to the MSD ignitions Gray wire as shown in Figure 15 MSD IGNITION 12120 ESTHER LAMA SUITE 114 EL PASO TEXAS 79936 915 857 5200 FAX 915 858 9241 INSTALLATION INSTRUCTIONS 9 SECTION V TIMING AND PROGRAMMING The MSD Watercraft Ignitions innovative design allows you to static time the engine before the engine is started Study the special features shown in Figure 18 before proceeding Holes for rotating Timin timing plate with adjustment allen wrenches Zw holes LED ae for allen 2 E wrenches Holes for l j loosening timing is Le Ee plate assembly PROG SWITCH Figure 19 How to Check Static Timing At this point in the installation the ignition coil and starter relay should be mounted and installed in the craft along with the trigger plate assembly and flywheel Now you are ready to time the engine before starting the engine 1 Locate Top Dead Center TDC by placing a dial indicator in the front cylinder and rotating the crankshaft until the piston reaches the highest point in the cylinder Figure 19 When TDC is found place a mark on the engine case so that it lines up with the TDC mark of t
6. OFF OFF OFF ON rp ea TIMING SETUP 84 8750 ON OFF OFF ON eet a LED OPERATE ON 9000 OFF ON IGN OPERATE OFF 9250 ON ON OFF ON 9500 OFF OFF ON ON 9750 ON OFF ON ON DESIRED PN 4272 10000 OFF ON ON ON 10250 ON ON ON RETARD MAX HOLESHOT MAX BEGIN 8 REV REV SPEED SPEED LIMIT LIMIT RETARD 921 2929 929221 HOLESHOT REV LIMIT MAX SPEED RETARD RPM 51 52 53 54 DEG 55 56 57 58 OFF OFF O OFF O 2 4 6 eo SUGGESTED PROGRAMMING POINTS ENGINE RPM RETARD BEGIN RETARD REV RETARD LIMIT 650 750 Kaw 5000 6000 3800 4200 RPM 8 7000 RPM 650 750 Kaw 6000 7000 4600 5000 RPM 8000 RPM 650 750 Kaw 6600 7600 5000 5600 RPM Ue 9000 RPM 650 701 760 Yam 5000 6000 3800 4200 RPM 8 7000 RPM 650 701 760 Yam 6000 7000 4600 5000 RPM 8000 RPM 650 701 760 Yam 6600 7600 5000 5600 RPM 9000 RPM 650 720 Sea Doo 5000 6000 3800 4200 RPM 7000 RPM 650 720 Sea Doo 6000 7000 4600 5000 RPM 8000 RPM 650 720 Sea Doo 6600 7600 5000 5600 RPM 9000 RPM MSD IGNITION 12120 ESTHER LAMA SUITE 114 EL PASO TEXAS 79936 915 857 5200 FAX 915 858 9241 14 INSTALLATION INSTRUCTIONS SECTION VI TROUBLESHOOTING After installing the MSD Ignition System if the craft fails to start check t
7. TEXAS 79936 915 857 5200 FAM 915 858 9241 INSTALLATION INSTRUCTIONS 3 The following are suggested areas to install the mounting plate to your craft Kawasaki 650 SX Remove the stock electrical box and mount the plate to existing mounting bosses Kawasaki X2 Attach ignition mounting plate under the hood latch mounting bolts Mount coil above engine next to the steering arm Kawasaki 750 SX SXi Remove the stock electrical box and mount the plate to existing SS Xi Xir Zxi mounting bosses Yamaha Blaster SuperJet Remove the stock electrical box and mount the plate to existing VXR WaveRunner mounting bosses Raider 701 760 BREAK HERE SECTION II INSTALLING THE SPARK PLUG WIRES Each wire set includes two 90 dual crimp terminals two MSD Heli Core Spark Plug Wires and a Mini Stripper Crimper The MSD Mini Stripper Crimper is supplied for assembling the MSD Spark Plug Wires Before using the tool it must be separated into two parts Separate it by bending the tool back and forth until the center breaks Figure 2 1 Locate the correct cutting groove of the Mini Stripper Crimper for your wire One groove is larger to accept the 8 5mm Super Conductor Wire Insert the wire from the long side of the crimper tool and push it through until it is flush with the other side Figure 3 Figure 3 Stripping the Wire 2 Press a single edge razor blade in the cutting groove and push all the way down Slowly rotat
8. engine rpm limit is set and where the timing retard ends at IGNITION 12120 ESTHER LAMA SUITE 114 EL PASO TEXAS 79936 915 857 5200 FAX 915 858 9241 12 INSTALLATION INSTRUCTIONS SETTING THE PROGRAM SWITCHES INITIAL TIMING A The LED indicated timing is 5 advanced from the actual run timing if switch 1 is set to on on on Refer to Section V Timing the Watercraft Ignition for proper setting SETTING MAX TIMING The max timing is 5 less than the LED indicated timing Max timing can be retarded up to 7 from the max timing setting by Selectors S1 S3 of switch Refer to Section V Timing the Watercraft Ignition for setting the max timing SETTING THE RETARD BEGIN SPEED Selectors 51 53 of switch 2 determines the rpm point at which the timing will begin to retard at The rom point is adjustable in 500 rom increments between 4000 rpm and 7500 rpm Position selectors S1 S3 of switch 2 to the desired retard begin speed for your particular combination D MAX SPEED REV RETARD LIMIT LED TIMING IS 5 ADVANCED FROM RUN TIMING 0 1K 2K 3K 4K 5K 6K 7K 8K RPM HOLESHOT LIMIT 3000 7250 RPM RETARD BEGIN o 55 MAX SPEED HOLESHOT MAX SPEED SPEED REV LIMIT REV LIMIT RETARD E 5 Figure 25 MAX SPEED REV RETARD LIMIT D The rev retard limiter function is variable in 250 rpm
9. engines the stock front engine cover will require modification The stock stator mounting bosses will have to be machined out of the front cover so that the MSD flywheel will fit If you do not have access to a machine shop you can also use a stock Kawasaki 650 SX front cover To modify the Kawasaki 750 flywheel cover machine the areas that are shaded in gray flush with the flywheel cover Figure 13 Note If the starter gear was removed Kawasaki 650 750 Yamaha 650 701 760 and Sea Doo engines only during the installation of the trigger plate install the gear now 1 2 3 IGNITION Place the flywheel in boiling water for five minutes to evenly heat the flywheel Position the Woodruff Key on the crankshaft After the flywheel is thoroughly heated quickly remove the flywheel from the water and install it onto the crankshaft With a flashlight look into the Woodruff Key slot and make sure the key is still in position Install the flywheel retaining nut bolt Attach a flywheel holding tool not supplied and torque the flywheel retaining bolt nut to Kaw 650 750 65 ft lbs Yam 650 701 760 65 ft lbs Sea Doo 100 ft lbs If the thickness of the clay is between ADD THESE SHIMS Figure 13 Modifying the Kawasaki 750 Front Cover 12120 ESTHER LAMA SUITE 114 EL PASO TEXAS 79936 915 857 5200 FAX 915 858 9241 INSTALLATION INSTRUCTIONS 7 SECTION IV WIRING All wires must be routed
10. increments between 6500 rpm and 10250 rpm The system is supplied with the rev retard limit pre set at 7750 rpm Position selectors 55 26 of switch 2 to the desired rpm retard limit point for your particular engine combination SETTING THE HOLESHOT LIMIT The Holeshot rev limit function is variable in 250 rom increments between 3000 rpm and 6750 rpm Position selectors S1 S4 of switch 3 to the desired rpm limit point for your application SETTING THE MAX RETARD F Selectors S5 S8 of switch 3 determines how much timing retard will occur between the Retard Begin rpm point and the Rev Limit rom point The Max Retard is adjustable in 1 degree increments from 0 to 15 degrees The retard is operational only when the Max Retard function is set to a value other than zero If the max retard is not desired the Max Retard function should be set to zero all selectors off Position selectors S5 S8 of switch 3 to the desired retard amount for your particular engine combination MSD IGNITION 12120 ESTHER LAMA SUITE 114 EL PASO TEXAS 79936 915 857 5200 FAX 915 858 9241 INSTALLATION INSTRUCTIONS 13 MAXIMUM TIMING RETARD BEGIN SPEED MAX SPEED REV LIMIT 52 53 DEG RPM 51 2 53 RPM 55 56 7 6 16 OFFI 4000 OFF OFF OFF 6500 OFF OFF OFF OFF 6 OFF ON ON 7000 OFF ON ON 8000 OFF ON OFF MAX LON ON ON 7500 _ ON ON ON 8250 ON ON OFF 8500
11. of true timing Note the MSD Digital Ignition can be programmed to electronically MSD IGNITION 12120 ESTHER LAMA SUITE 114 EL PASO TEXAS 79936 915 857 5200 FAX 915 858 9241 TDC MARK we 10 INSTALLATION INSTRUCTIONS retard the timing up to 7 less than what the maximum true timing is set at Always set the trigger plate for the maximum amount of timing the engine will ever run at 5 To adjust the ignition s max timing the trigger plate must be rotated counter clockwise to advance the timing or clockwise to retard the timing To adjust the plate without removing the flywheel locate the four trigger plate access holes in the flywheel Figure 21 Rotate the flywheel back to TDC and then insert two 4mm allen wrenches into the holes that line up with the trigger plate hold down bolts Loosen the bolts to allow the trigger plate to be rotated 6 Remove the two wrenches and rotate the flywheel to the timing mark that was previously recorded Insert the two allen wrenches into the other two holes located 90 to the first two holes so the trigger plate rotates with the flywheel Rotate the flywheel clockwise or counter clockwise until the desired timing mark on the flywheel lines up with the timing mark on the engine Figure 22 7 Remove the two wrenches and rotate the flywheel to TDC Insert the allen wrenches into the first two holes that line up with the trigger plate retaining bolts and tighten th
12. to the locations described then cut to length and have Perma Seal solderless connectors installed as shown in Figure 14 Applying a small amount of heat to the connector seals the wire to terminal connection Figure 14 Installing Perma Seal Connectors MSD CABLE IDENTIFICATION Figure 15 shows a complete installation of the MSD Watercraft Ignition System Connecting The Power Leads Before connecting the power leads clean all surfaces of dirt paint and other foreign substances where the power leads will be connected If the power leads need to be lengthened use 14 gauge wire and solder all splices Power leads may be shortened if necessary 1 Connect the Red wire directly to the battery positive post or to the starter solenoid where the cable from the battery is connected 2 Connect the Black wire to ground preferably on the engine where the ground strap from battery is connected to the engine case Connecting the Ignition 1 Connect the ORANGE wire from the ignition to the ORANGE wire from the coil 2 Connect the BLUE wire from the ignition to the BLACK wire from the coil 3 Connect the two GREEN wires from the ignition to the two GREEN wires from the trigger pickup HOLESHOT SWITCH PN 4372 LT BLUE TRIGGER PICKUP 5 BLACK ORANGE BLACK GRAY_ 8000 RPM ORANGE BLUE TACH ON OFF SWITCH TIMING PLATE 6 VIOLET INDICATES BATTERY CONNECTION O LANDYARD SWITCH STARTER RELAY PN
13. MSD Ignition Kill Lanyard PN 43731 ET E Wave Raider WaveRunner PN 4396 1 Momentary On Off Switch MSD PN 4372 All Sea Doo PN 4397 Tools Required 1 Wire Terminal Crimper 1 4mm Allen Wrench 1 Heat Gun 1 Phillips Screw Driver 1 Caliper or Measuring Device 1 1 2 Drive Rachet 1 Clay or Soft Wax 1 1 2 x 30mm Socket Sea Doo Only 1 Flywheel Puller 1 1 2 x 14mm Socket 650 750 Kaw Eng Only 1 Flywheel Holder 1 1 2 x 17mm Socket 650 701 Yam Eng Only 1 Single Edge Razor Blade 1 Torque Wrench IGNITION 12120 ESTHER LAMA SUITE 114 EL PASO TEXAS 79936 915 857 5200 FAX 915 858 9241 INSTALLATION INSTRUCTIONS For ease of installation these instructions are divided into sections Section l Mounting the Ignition Coil and Starter Relay Section II Installing the Spark Plug Wires Section Ill Installing the Flywheel and Trigger Pickup Assembly Section IV Wiring the Ignition System Cable Identification Connecting the Power Leads Section V Timing the Ignition Programming the Ignition Section VI Troubleshooting Section VII Customer Service amp Warranty SECTION MOUNTING THE IGNITION COIL STARTER RELAY The MSD Watercraft Ignition may be mounted in any location except on the engine or near the exhaust manifold Excessive heat at these locations could damage the ignition It is recommended that a mounting plate be fabricated out of aluminum or stainless steel a
14. close the jaws of the vise 8998988988 Make sure that the crimp is ea properly forming and that the PUSH IN tool remains aligned Stop when the ends of the terminal have curled tightly into the wire sleeve but do not tear into the sleeve Figure 6 DO NOT overcrimp the wire Figure 6 Installing the Wire and Crimping Figure 7 Postioning the Terminal in the Boot 8 Apply dielectric non conductive lubricant to the inside of the boot Grasp the boot and push the wire with the terminal into the boot until the terminal stops at the boot s 90 bend Make sure the terminal is positioned in the boot so the open side of the terminal faces the open side of the boot Figure 7 9 Apply a light coat of dielectric grease to the spark plug and the coil spark plug wire tower and install the wire onto the engine MSD IGNITION 12120 ESTHER LAMA SUITE 114 EL PASO TEXAS 79936 915 857 5200 FAX 915 858 9241 INSTALLATION INSTRUCTIONS 5 SECTION 111 FLYWHEEL AND TRIGGER PLATE REMOVAL Before installing the MSD Flywheel and Trigger Pickup assembly the stock magneto flywheel and stator plate must be removed Refer to your crafts service manual for the proper removal procedure TRIGGER PLATE ASSEMBLY 1 Assemble the trigger plate and pick up assembly as shown in Figure 8 Place the trigger plate assembly on the bosses with the trigger on the side of the engine where the wires normally exit the case Figure 9
15. e bolts 8 Rotate the flywheel clockwise until the LED turns on Check to make sure the desired timing has been set correctly Install the flywheel cover Figure 22 Moving the Trigger Plate to Adjust the Timing 9 To program the engines final maximum timing setting position selectors 51 53 of switch as required to match the desired timing Example indicated timing is 25 less 3 selectors S1 S3 set for 3 22 maximum timing 10 Turn the ignition switch to the OFF position and position selector S4 of switch 2 to off position Install the spark plugs and spark plug wires The engine is now ready to start Note If the application you are installing the system on permits verify the ignition timing using a timing light PROGRAMMING The function of the timing curve is to match the ignition HIGH SPEED RETARD to the burning rate of the fuel and the speed RPM of See the engine By adjusting the timing of the ignition lt m maximum combustion pressure can be achieved at the rT lt same time the piston is beginning the power stroke Any j factor that changes the burning rate of the fuel or the START POINT engine speed RPM can cause a need for an ignition timing change RETARD START POINT RPM 8 RATE OF RETARD C ENGINE PROTECTION START POINT RPM TIMMING DEGRESS BTDC 6 000 7 000 8 000 RPM To the right is a chart of some of the factors that will a
16. e for most watercraft but changes can be made for special applications Three switches located under the aluminum plate of the MSD ignition module select the programming options Figure 24 IMPORTANT NOTE If the selector switch settings are changed the ignition switch must be turned off and back on before the new program functions become active Always install aluminum backing plate to seal switches RETARD MAX MAX SPEED HOLESHOT MAX SPEED TIMING REV LIMIT REV LIMIT RETARD L 1 2 5 SWITCH 1 SWITCH 3 The factory settings are Switch 1 Selectors 51 0 S2 on S3 on Max Timing 0 Switch 2 Selectors 51 0 S2 on S3 off Begin Retard 5000 rpm S4 off Timing Setup Ignition Operate 55 0 S6 off S7 on S8 off Rev Limit 7750 rpm Switch 3 Selectors 51 0 S2 on S3 off S4 off Holeshot Rev Limit 3500 rpm 5 on S6 on S7 on S8 off Max Speed Retard 7 Figure 24 Programming Switches TIMING RETARD FUNCTION The max speed retard function is an rom dependent timing retard It is configured by three seperate elements 1 The Retard Begin Speed C Fig 25 is the point in the rom range when the timing retard begins 2 The Total Retard F Fig 25 is the total amount of timing retard in crankshaft degrees introduced between the retard begin point and the Rev Limit point 3 The Rev Limit D Fig 25 is the point in the rom range where maximum safe
17. e the wire 360 then remove the razor blade Remove the wire from the Crimper and slowly twist the cut end of wire off in a counterclockwise direction 3 Before crimping the terminals to the wires the terminals must be modified as shown in Figure 4 Bend the terminal ears over 90 by using a pair of regular needle nose or long nose pliers CONDUCTOR 3 CRIMP TABS hr CONDUCTOR 4 Position the wire in the terminal until the insulation sleeve is about 1 8 beyond its crimping tabs Position the conductor between the conductor crimps and use a pair of needle nose pliers to crimp the tabs tightly against the conductor Figure 5 Make sure the conductor does not slide out and do not overtighten Figure 5 Installing the Terminal MSD IGNITION 12120 ESTHER LAMA SUITE 114 EL PASO TEXAS 79936 915 857 5200 FAX 915 858 9241 4 INSTALLATION INSTRUCTIONS 5 After positioning the conductor position the terminal wire assembly into the W groove side of the Mini Crimper Align the tabs so they are exactly p centered on the point Figure a i FLAGS 6 l 6 Slide the stripper block over the crimping block Push the wire and terminal in the rest of the way by lightly squeezing the Mini Stripper Crimper together Make sure the Vise Flags are on the same side and that they are pushed against the vise jaws to ensure correct alignment DIE ane Figure 6 LUBRICANT 7 Slowly
18. ffect ignition timing Figure 23 Programming Points IGNITION 12120 ESTHER LAMA SUITE 114 EL PASO TEXAS 79936 915 857 5200 FAM 915 858 9241 INSTALLATION INSTRUCTIONS 11 As you can see from the chart most FACTOR ADVANCE FOR RETARD FOR factors will change Cylinder Pressure Low High throughout the range RPM Engine Low High of engine operation Energy of Ignition Low High Timing adjustments Fuel Octane High Low must be made to Mixture Fuel Air Rich Lean compensate for these Temperature Cool Hot changes Combustion Turbulence Low High Obviously a full Load Light Heavy technical explaination of the correct ignition timing would be very complicated The best way to arrive at a suitable timing curve for your engine is to use the above chart as a guide and compare your engine combination against the chart TIPS FOR SETTING YOUR IGNITION TIMING 1 Use as much initial advance as possible without encountering excessive starter load or engine kickback on starting Beware of detonation when setting the initial advance 2 Set the timing retard start point as early as possible without sacrificing low RPM performance 3 Use the highest retard as possible without hurting top end performance PROGRAMMING THE IGNITION The MSD Ignition produces a computer generated timing curve Several programming options are available to tune the basic timing curve to meet specific engine requirements The factory program settings are suitabl
19. h you have them installed Be sure to include a detailed account of any problems experienced and what components and accessories are installed on the vehicle The repaired unit will be returned as soon as possible after receipt COD for any charges For more information call the MSD Customer Service Line 915 857 5200 MSD technicians are available from 8 00 a m to 5 00 p m Monday Friday mountain time Limited Warranty Autotronic Controls Corporation warrants MSD Ignition products to be free from defects in material and workmanship under normal use and if properly installed for a period of one year from date of purchase If found to be defective as mentioned above it will be replaced or repaired if returned prepaid along with proof of date of purchase This shall constitute the sole remedy of the purchaser and the sole liability of Autotronic Controls Corporation To the extent permitted by law the foregoing is exclusive and in lieu of all other warranties or representations whether expressed or implied including any implied warranty of merchantability or fitness In no event shall Autotronic Controls Corporation be liable for special or consequential damages FRM18680 Revised 06 97 Printed In U S A
20. he far left timing mark on the flywheel as shown in figure Figure 20 2 Remove the ignitions backing plate Position switch 1 to ON ON ON Position selector S4 of switch 2 to ON in order to disable the ignition s spark and activate the built in LED indicator Turn the ignition on off switch to the ON position and place the spark plugs with spark plug wires attached against ground WARNING Do not trigger the ignition without the Figure 19 Finding Top Dead Center spark plugs grounded and the plug wires attached Damage to the ignition coil may result 3 Slowly rotate the flywheel clockwise until the small LED on the side of the ignition turns on When the LED is on this indicates that the magnet on the flywheel is entering over the trigger pickup and that the ignition will fire at this point Note As the flywheel is rotated the timing marks will decrease from a high number to a low number Each dimple on the flywheel j A represents 5 of timing adjustment with the first K dimple being TDC A 4 Follow the timing mark on the engine down to sn the flywheel and determine where the timing Figure 20 Marking TDC is set at by reading the timing mark on the flywheel Write this number down Because of the advanced circuitry in the MSD Ignition the true timing is 5 less than what the timing mark will show To achieve your true timing subtract 5 from the number you wrote down Example shown 30 less 5 equals 25
21. he installation procedure for any missed steps If everything checks correctly inspect the following 1 Check the battery to make sure it is fully charged and properly connected Also make sure the terminal connections are clean and tight 2 Make sure there are no loose wire connections All connections should be free of rust paint or other debris 3 Visually check the connections on the coil Only two wires should be making contact to the coil wires Orange should be connected to the Orange wire on the coil and the blue wire should be connected to the Black wire on the coil Do Not connect any test equipment test lights etc to the coil wires 4 Check the Ignition s heavy Red wire for 12 volts If 12 volts is not there check the connections or battery condition 5 Check for 12 volts on the Violet wire of the MSD Ignition when the ignition on off switch is in the ON position 6 Check the craft s safety lanyard for proper operation 7 Check the programming switch S4 of switch 2 Timing check ignition operate position If there is still a problem present after checking all of the above steps continue with the following diagnostic procedures TESTING THE IGNITION FOR SPARK After checking the wiring through the Troubleshooting Check List and the schematic on page 7 of the instructions test the MSD Ignition to make sure that it is sparking If the ignition produces a spark in this test then it can be assumed that the ignition
22. is functioning properly To check for spark follow this procedure 1 Make sure the ignition switch is in the Off position 2 Remove the spark plugs then connect the spark plug wires to the plugs and position them so you can observe the spark jump the plug gap The plugs must be grounded 3 Cut the two green trigger wires from the trigger pickup When finished with this test you must connect the wires together following the wiring tips discussed earlier in this manual 4 Turn the ignition switch On Do Not attempt to crank the engine 5 Take a short length of wire and jump the two Green wires from the ignition together then release them quickly several times When you do this a spark should jump the spark plug gap 6 If there is no spark substitute another ignition coil and repeat the test TESTING THE TRIGGER PICKUP After checking the Ignition Module you can test the operation of the trigger pickup Note The two Green trigger pickup wires must be connected at this time 1 The MSD Ignition s Red wire should be disconnected from the battery or starter solenoid while turning the engine by hand Turn the ignition switch to the On position NOTE This can be left connected if the timing check switch is moved to the LED operate position The switch must be in the LED position to check pickups or timing 2 While observing the LED on the side of the ignition rotate the crankshaft by hand When the pickup and the magnet on the fl
23. nd the ignition coil and starter relay be mounted to it Use the template supplied to assist you in making a mounting plate for your craft When selecting a mounting location make sure that the ignition s cable assembly will reach the battery and flywheel areas To simplify installation MSD offers mounting plates for most applications Figure 1 These strong aluminum plates are pre drilled and attach to the factory mounting locations Part numbers are listed on page 1 Ignition Using the Ignition as a template mark the location of the mounting holes on the mounting plate Remove the ignition and drill a 1 4 hole at each marked location Mount the ignition using 10 32 x 3 4 or 5mm x 16mm stainless steel bolts not supplied Ignition Coil Using the coil as a template mark the location of the mounting holes Remove the coil and drill a 1 4 hole at each marked location Mount the coil using 1 4 x 3 4 or 6mm x 20mm stainless steel bolts not supplied Starter Relay When installing the MSD Watercraft Ignition System it may be necessary to remove the stock starter relay and replace it with an MSD External Relay PN 4390 Using the relay as a template mark the location of the mounting holes Remove the relay and drill a 1 4 hole at each marked location Mount the coil using 1 4 x 1 2 or 6mm x 12mm stainless steel bolts not supplied Figure 1 An MSD Mounting Plate IGNITION 12120 ESTHER LAMA SUITE 114 EL PASO
24. ywheel line up the LED should illuminate 3 If the LED lights the trigger pickup is operating properly If the LED does not light when switch 2 S4 is on check the air gap between the pickup and the flywheel magnet It should be 050 094 If the air gap is correct the trigger pickup is at fault NOTE Timing setup switch S4 must be in LED operate position IGNITION 12120 ESTHER LAMA SUITE 114 EL PASO TEXAS 79936 915 857 5200 FAM 915 858 9241 INSTALLATION INSTRUCTIONS 15 If you perform all the above suggestions and still have problems or have any questions concerning the installation or operation of your MSD Watercraft Ignition Kit call the MSD Watercraft Customer Service Department for more information TECH NOTES MSD IGNITION 12120 ESTHER LAMA SUITE 114 EL PASO TEXAS 79936 915 857 5200 FAX 915 858 9241 TECH NOTES Service In case of malfunction this MSD component will be repaired free of charge according to the terms of the warranty When returning MSD components for service Proof of Purchase must be supplied for warranty verification After the warranty period has expired repair service is charged based on a minimum and maximum charge Send the unit prepaid with proof of purchase to the attention of Customer Service Department Autotronic Controls Corporation 12120 Esther Lama Suite 114 El Paso Texas 79936 When returning the unit for repair leave all wires at the length in whic
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