Mallory Ignition 61008M, 61009M User Manual

FORM 1503 6/04

INSTALLATION INSTRUCTIONS

E-SPARK™ BREAKERLESS CONVERSION KIT

FOR MALLORY POINT DISTRIBUTORS

NOTE: This product is legal in California only for racing vehicles which may never be operated upon a highway.

IMPORTANT

All kits listed below must be used with an ignition ballast resistor (or loom resistance wire) to prevent
module failure. If your vehicle is not equipped with a ballast resistor or loom resistance wire, Mallory
Ballast Resistor (Part No. 700) or Mallory Coils 29219, 29450 or 30450 (which are internally ballasted)
may be used.

These kits do not work with vacuum advance distributors.

APPLICATIONS

Part No. 61004M Mallory 8 cylinder point distributors

(automotive and marine) which use
a standard stack cap (Part No. 209
or 209D)

Part No. 61005M Mallory 8 cylinder point distributors

(automotive and marine) which use
a flat cap (Part No. 221 or 221B)

Part No. 61006M Mallory 6 cylinder point distributors

(automotive and marine) which use
a standard stack cap (Part No. 270
or 270B)

Part No. 61007M Mallory 6 cylinder point distributors

(automotive and marine) which use
a mini bowl cap (Part No. 226
or 226B)

Part No. 61008M Mallory 4 cylinder point distributors

(automotive and marine) which use
a standard stack cap (Part No. 271
or 271B)

Part No. 61009M Mallory 4 cylinder point distributors

(automotive and marine) which use
a mini bowl cap (Part No. 225
or 225B)

WARNING

You must install the E-Spark™ Conversion Kit
exactly as shown in these instructions. After the
kit is installed—and before you start the engine—
check all wiring again. Mis-wiring will cause the
E-Spark™ Ignition to fail immediately.

INSTALLATION

Step 1

Remove the cap and rotor, then remove the con­denser. Remove the plastic insulators (see Figure 1).

Step 2

Loosen the 2 nuts that hold the cap clips/brackets in
place (see Figure 1).

NOTE: To loosen the nuts on a marine distributor,
the aluminum pins in the brackets may need to
be cut in two and removed. Replacement pins
are provided.

Step 3

Remove the point plate assembly by lifting it out of
the housing (see Figure 1).

Point Plate

FIGURE 1

PARTS INCLUDE IN THIS KIT:

1 E-Spark™ Plate Assembly
1 Wire Harness
1 Rotor/Shutter Wheel Assembly (PN 559 contains 2

rotor/shutter wheel assemblies)
1 Wire Connector
1 Grommet, 3-Hole (Marine Approved)
2 Pins, Aluminum
1 Thrust Button

MALLORY IGNITION www.mrgasket.com

Insulators

Cap Clip Nuts

Condenser

1

Step 4

Use a 2-arm or 3-arm puller and the thrust button
(provided) to remove the cam from the rotor sleeve
(see Figure 2).

WARNING: Do not try to remove the cam by
prying on it with a screwdriver(s). This will
damage the advance assembly.

Step 5

Install the E-Spark™ plate assembly into the housing.
Make sure that the cut-out in the plate is directly
below the hole in the housing where the wires will exit
(see Figure 3).

Step 6

Tighten the two nuts that hold the cap clips/brackets
in place. This also secures the E-Spark™ plate.

Step 7

Marine Distributors Only

Replace the cap clips using the new aluminum pins
provided.

Step 8

Install the wire grommet. Lubricate the wires with light
oil. Run the wires through the grommet and out of the
distributor housing (see Figure 3).

FIGURE 2

Puller

Thrust Button

Remove button
after cam has
been removed

Cam

Step 9

Install the connector onto the wires. Be sure the wires
are in the correct positions (see Figure 4).

Step 10

Install the rotor/shutter wheel assembly. Make sure
that the rotor is fully seated and that it does not rub
the module wires. Replace the cap.

Step 11

If you removed the distributor to install the E-Spark™
Conversion Kit, reinstall the distributor in the engine.

Step 12

Connect the wire harness to the connector. Connect
the 3 wires to the correct locations, as shown in
Figures 5 and 6.

Step 13

Set the ignition timing. Start the engine and recheck
timing.

FIGURE 4

Female Connector

Red

Brown

Green

▼

Distributor Wire Harness

Red
Brown
Green

FIGURE 3

Grommet

E-SPARK Plate
Assembly

Connector

Index Rib

2

MALLORY TECHNICAL SUPPORT [phone] www.mrgasket.com