6
INSTALLATION INSTRUCTIONS
MSD IGNITION
• 12120 ESTHER LAMA, SUITE 114, EL PASO, TEXAS 79936 • (915) 857-5200 • FAX (915) 858-9241
Figure 11 Checking the Air Gap.
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. Position a small amount of clay on the top of
the trigger pickup (Figure 11).
2. Place the flywheel on the crankshaft and lightly
tap with a rubber or wooden object to hold it
in place.
3. Remove the flywheel and measure the
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".
4. 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.
Note:
On Kawasaki 750 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. Place the flywheel in boiling water for five minutes
to evenly heat the flywheel.
2. Position the Woodruff Key on the crankshaft.
3. 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.
4. 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.
Figure 12 Air Gap Shim Chart.
Figure 13 Modifying the Kawasaki 750
Front Cover.
SHIM CHART
If the thickness
of the clay is
between:
.050" - .094"
.095" - .115"
.116" - .135"
.136" - .155"
.156" - .176"
.176" - .195"
ADD THESE SHIMS
.020" .060"
0 0
1 0
2 0
0 1
1 1
2 1
