Yamaha BANSHEE Service manual

MSD Enhancer Ignition
for the Yamaha Banshee
PN 05-09-2615/PN 4204
Parts Included:
1 - Programmable Enhancer Ignition, PN 05-09-2615/PN 4204
Parts Required: (Not Included)
1 - MSD 7.2 Volt NiCad Fast Charger (1 Hour),
PN 00-00-1530/PN 4385
1 - Clutch Lever Micro Switch for Holeshot Feature
1 - MSD Coil Assembly, PN 30-00-3010/PN 4294
1 - Ignition Mounting Brackets, PN 15-04-0530/PN 4393
1 - MSD 7.2 Volt NiCad Battery, PN 00-00-2625/PN 4381
1 - Battery Mounting Bracket, PN 00-00-2626/PN 43811
Tools Required
#3 Phillips Screwdriver
3/8” Ratchet
10mm Socket
10mm Open End Wrench
Optional PN 05-09-4214/PN 4214
Charging Circut
Note: It is recommended that you have the
factory service manual while performing this
installation.
TECHNICAL INFORMATION
Spark Output: The MSD Enhancer Ignition System for the Yamaha Banshee produces a high
output spark that is approximately double the stock spark output. This increased spark energy
allows the use of richer fuel mixtures or even exotic fuel such as alcohol. The MSD Enhancer
Ignition will put out approximately 30,000 volts to the spark plug.
Spark Plugs: With the MSD Enhancer, it is recommended to use as cold a spark plug as possible
while still being able to start the engine easily. The spark plug gap will largely depend on the
compression of the engine. The higher the compression the smaller the plug gap you must run. A
good rule of thumb for the spark plug gap is between .032” and .036”. Taking the time to test with
different gaps will give you the best gap for your application.
MSD Coil and Spark Plug Wires: The MSD Coil features low resistance (0.2 Ohms Primary, 2K
Ohms Secondary) with a turns ratio of 70:1 for maximum spark voltage and energy. The MSD
8.5mm Super Conductor Spark Plug Wires are very low resistance (less than 50 Ohms per foot) for
maximum voltage carrying capabilites. Even with this low resistance, the wire still suppresses EMI
(Electro Magnetic Interference) from disrupting the electronics of the ignition. This is the only wire
recommended to be used with the MSD Enhancer Ignition System.
Adjustable Ignition Timing Curve: The MSD Enhancer Ignition system allows you to program an
ignition timing curve. Changes in altitude, compression, fuel octane or a number of other variables
requires that the ignition timing be compensated. The MSD Enhancer allows you to advance or
retard the initial timing as well as designate a different timing curve to increase overall power and
performance.
Holeshot Feature: The feature allows the user to program an rpm-limit, which enables the rider to
leave the starting line quicker.
Rev Limiter: The MSD Enhancer does not have an adjustable rev limiter. The Ignition will not turn
over 13,500 rpm.
MSD POWERSPORTS
• 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
2
INSTALLATION INSTRUCTIONS
7.2 Volt NiCad Battery: The MSD
Enhancer Ignition System depends
on a 7.2 volt battery source to supply
power to the complex adjustable timing feature. The NiCad battery that is
supplied with the Enhancer ignition
is rated at 600 mah. This will provide
approximately two hours of continuous ride time. This can be extended
by purchasing a 7.2 volt NiCad battery from a local hobby shop. These
batteries are available from 1400 to
1800 mah. The MSD NiCad battery
can be charged with the MSD Fast
Charger, PN 00-00-1530/PN 4385.The
MSD Fast Charger is a 12 volt charger that will fully recharge the battery
in about one an hour from your car’s
cigarette lighter.
Figure 1 The MSD Charging System.
OUTSIDE TOP MOUNT
FRAME
Although it will not hurt the ignition
to leave the battery plugged in, it will
produce a slight current draw on the
battery causing it to discharge over
an extended period of time. Also
Figure 2 Mounting the Enhancer.
available is the MSD Charging Circut,
PN 05-09-4214. The Charging Circuit will trickle charge the battery as you ride. One end of the
Charging circuit plugs in between the CDI and NiCad battery. The other end plugs in to your stock
voltage regulator, which supplies the power to charge the battery.
IGNITION
REMOVAL
In order to install the MSD Enhancer ignition system the factory CDI box and coil must be disconnected
or removed. Refer to the factory service manual for the proper removal. Note: Do not mix the Factory
Yamaha Coil and CDI unit with any MSD Components as severe damage may occur.
INSTALLATION
The MSD Enhancer Ignition is designed to mount between the front A-arms on the frame (Figure
2). Four mounting straps are supplied with the kit to hold the ignition to the frame.
1. Position the Enhancer ignition between the two A-arms but do not tighten it yet. Make sure the
wire harness is routed towards the rear of the bike.
2. Route the wires with the 4-pin connector down the right side of the frame to the factory 4-pin
connector from the engine magneto.
NOTE: Some early model Yamaha Banshees use a different wiring connector than the one supplied
in this kit. Use the following chart to splice the MSD Enhancer harness to the Banshee (Figure 3).
Stock Banshee
Red
Green
White/Green
White/Red
MSD Enhancer
Red
Violet
Green
Yellow
Figure 3 Wiring Harness Change for Early Models.
MSD POWERSPORTS
• 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
INSTALLATION INSTRUCTIONS
3
3. Plug these two connectors together and
secure them to the frame.
4. Using the hardware from the stock coil,
mount the MSD Coil assembly to the
factory coil bracket. Refer to the coil
instructions for cutting and crimping the
spark plug wires.
5. Route the Enhancer’s Orange and Brown
wire assembly to the coil and connect
them to the MSD coil.
6. Find the solid Black wire on the MSD
Enhancer Ignition that has a ring lug
attached. This will be the ignition ground
Figure 4 Connecting the MSD Kill Switch (White Wire).
and needs to be directly attached to the
engine. Clean off any paint and attach securely to the engine.
7. The White wire controls the kill function of the ignition system. It can be connected one of two
ways:
A. If you do not want the Throttle OverRide System (TORS) to be functional then disconnect
the Black/White wire from the ignition kill switch on he handle bar and attach the White wire to
the Black/White wire that goes to the ignition kill switch.
B. If you want to retain the TORS unit splice the White wire from the Enhancer into the Black/
White wirE (Figure 3).
Note: The Stock Key switch will no longer function
for ignition kill.
8. The Light Blue wire controls the “Holeshot” feature
of the Enhancer Ignition System. When this wire
is connected to ground the ignition will go into a
low rpm rev limit. Typically this wire is connected
to a clutch lever actuated switch (Figure 3).
9. The NiCad battery mounts between the gas tank
and the plastic body. Mount the battery to the
mounting plate and slide the assembly between
Figure 5 Mounting the NiCad Battery.
the plastic and the tank. Bolt both pieces to the
tank with the original hardware (Figure 4).
10. Route the Red and Black wire from the Enhancer
ignition to the battery. Make sure they are clear of any exhaust components and secure them to
the frame.
Note: It is recommended to disconnect the battery after every ride to preserve the
battery life.
MSD POWERSPORTS
• 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
4
INSTALLATION INSTRUCTIONS
PROGRAMMING
One of the many advanced features of the Enhancer Ignition System is the ability to program
different timing options into the ignition system. This is especially important when making any
engine modifications or running special fuels.
Note: After making any program changes you must disconnect the power from the unit and then
reconnect it before the changes will take place.
40
35
30
MAX
25
MIN
20
15
10
9000
8000
7000
6000
5000
4000
3000
RPM
2000
TDC
1000
5
Figure 6 Max Timing Adjustments
Max Timing
Max Timing refers to the initial timing of the engine. Most systems require you to reposition the
stator plate to advance or retard the ignition timing. The MSD Enhancer Ignition only requires you
to select the maximum desired timing. The MSD Enhancer comes factory set at 23° of timing. This
can be verified by looking at the first set of switches and making sure they are in the Off, On, and
Off positions. The chart below shows the timing graph of the Enhancer as it is shipped from the
factory and then the different Max Timing settings that can be achieved by changing just the Max
Timing switches (Figure 5).
Holeshot Rev Limit
The Holeshot Rev Limiter switches controls the rpm point that the engine will be at when the light
blue wire is activated. The first four switches (S1, S2, S3, S4, of the eight switch panel control the
Holeshot rpm limits. Figure 6 shows the different switch settings. Adjustable between 3,000-10,500
RPMs in 500RPM increments.
MSD POWERSPORTS
• 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
INSTALLATION INSTRUCTIONS
5
40
35
MAX TIMING AT 2300 RPM
30
BEGIN RETARD 4000 RPM
25
20
STOCK TIMING
15
10
5
13,500
13,000
12,000
11,000
10,000
9000
8000
7000
6000
5000
4000
3000
2000
RPM
1000
TDC
Figure 7 Max Speed Retard Adjustments
Figure 8 Selecting a Holeshot Setting.
MSD POWERSPORTS
• 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
6
INSTALLATION INSTRUCTIONS
TECH NOTES
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
MSD POWERSPORTS
• 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
INSTALLATION INSTRUCTIONS
7
TECH NOTES
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
MSD POWERSPORTS
• 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
TECH NOTES
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________
Service
In case of malfunction, this component will be repaired free of charge according to the terms of the warranty. When
returning 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, MSD Powersports,
1490 Henry Brennan Dr., El Paso Texas 79936.
When returning the unit for repair, leave all wires at the length in which 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/Cashiers Check for any charges. For more
information, call the MSD Powersports Customer Service Line (915) 858-3365. MSD Powersports technicians are available
from 8:00 a.m. to 5:00 p.m. Monday - Friday (Mountain Time).
Limited Warranty
MSD Powersports warrants this product to be free from defects in material and workmanship under its intended normal
use* and if properly installed, for a period of one year from the date of original purchase. If found to be defective as mentioned
above, it will be repaired or replaced at the option of MSD Powersports. Any item that is covered under this warranty will be
returned free of charge through standard shipping methods. If faster service is required the customer has the option of paying
for this service.
This shall constitute the sole remedy of the purchaser and the sole liability of MSD Powersports. 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 MSD Powersports or its suppliers be liable for special or
consequential damages.
*Intended normal use means that this item is being used as was originally intended and for the original application as sold
by MSD Powersports. Any modifications to this item or if it is used on an application other than what MSD Powersports markets
the product, the warranty will be void. It is the sole responsibility of the customer to determine that this item will work for the
application they are intending. MSD Powersports will accept no liability for custom applications.
MSD POWERSPORTS
FRM26198
• 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
Revised 09/04
Printed In U.S.A.