MSD Ignition 4242, 4243, 4244 Installation Instruction

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 & Yam. 650/701/760 Models Only)
2 - 14 x 6.4mm Compression Washer ( Kaw. 650/750 & Yam. 650/701/760 Models Only)

Parts Not Included But May Be Required

1 - Starter Relay, MSD PN 4390
1 - Waterproof On/Off Switch, MSD PN 4370
1 - MSD Ignition Kill Lanyard, PN 43731
1 - Momentary On/Off Switch, MSD PN 4372

Tools Required

1 - 4mm Allen Wrench
1 - Phillips Screw Driver
1 - 1/2" Drive Rachet
1 - 1/2 x 30mm Socket (Sea Doo Only)
1 - 1/2 x 14mm Socket (650/750 Kaw. Eng. Only)
1 - 1/2 x 17mm Socket (650/701 Yam. Eng. Only)
1 - Torque Wrench

MSD IGNITION • 12120 ESTHER LAMA, SUITE 114, EL PASO, TEXAS 79936 • [phone] • FAX [phone]

Ignition Mounting Plates:
Kawasaki 750 SX, SXi, PN 4395
Yamaha Super Jet, Blaster, VXR,
Wave Raider, WaveRunner, PN 4396
All Sea Doo, PN 4397

1 - Wire Terminal Crimper
1 - Heat Gun
1 - Caliper or Measuring Device
1 - Clay or Soft Wax
1 - Flywheel Puller
1 - Flywheel Holder
1 - Single Edge Razor Blade

2 INSTALLATION INSTRUCTIONS

For ease of installation, these instructions are divided into sections.
Section I: Mounting the Ignition, Coil and Starter Relay
Section II: Installing the Spark Plug Wires
Section III: 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 & Warranty

SECTION I

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 and
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.

MSD IGNITION • 12120 ESTHER LAMA, SUITE 114, EL PASO, TEXAS 79936 • [phone] • FAX [phone]

INSTALLATION INSTRUCTIONS

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.

3

Yamaha Blaster, SuperJet
VXR/WaveRunner,
Raider 701/760

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 Mini­Stripper-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 Mini­Stripper-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).

Remove the stock electrical box and mount the plate to existing
mounting bosses.

Figure 2 Separating the Mini-Stripper.

Figure 3 Stripping the Wire.

2. Press a single edge razor blade in the cutting groove
and push all the way down. Slowly rotate 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

Figure 4 Preparing the Terminals.

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.

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.

MSD IGNITION • 12120 ESTHER LAMA, SUITE 114, EL PASO, TEXAS 79936 • [phone] • FAX [phone]

Figure 5 Installing the Terminal.

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
centered on the point (Figure

6).

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.

Figure 6 Installing the Wire and Crimping.

Make sure the "Vise Flags" are
on the same side and that they
are pushed against the vise jaws
to ensure correct alignment
(Figure 6).

7. Slowly close the jaws of the vise.
Make sure that the crimp is
properly forming and that the
tool remains aligned. Stop when
the ends of the terminal have

Figure 7 Postioning the Terminal in the Boot.

curled tightly into the wire sleeve
but do not tear into the sleeve
(Figure 6). DO NOT overcrimp
the wire!

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 • [phone] • FAX [phone]

INSTALLATION INSTRUCTIONS

SECTION III 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 craft’s 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). 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.

5

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
for a 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.

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

Figure 9 Mounting the Trigger Plate

approximately 1/16" play on each side.

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 8 Assembling the Trigger

Plate.

Assembly.

Figure 10 Modifying the Kawasaki 750 Case.

MSD IGNITION • 12120 ESTHER LAMA, SUITE 114, EL PASO, TEXAS 79936 • [phone] • FAX [phone]