MSD Enhancer Ignition for the
Honda TRX400EX
PN 05-00-4203/PN 4203
Parts Included:
1 - Programmable Enhancer Ignition
1 - MSD Coil Assembly
1 - Ignition Mounting Brackets
Parts Required: (Not Included)
1 - Clutch Lever Micro Switch for Holeshot Feature
1 - Y-Splice
1 - Black Ground Wire
Note: It is recommended that you have the factory service manual while performing this installation.
TECHNICAL INFORMATION
Spark Output: The Enhancer Ignition System for the Honda 400EX 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 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 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 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 MSD Enhancer Ignition has a special built-in circuit that sets a low rpm limit. This rpm limit produces consistent and quick starts. This allows you to concentrate on the start of the race instead of throttle position.
Rev Limiter: The MSD Enhancer Ignition max speed rev limiter is adjustable from 8,750 to 12,500 rpm.
MSD POWERSPORTS • 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
2 INSTALLATION INSTRUCTIONS
REMOVAL
Refer to the factory service manual for the proper removal.
Note: Do not mix the Factory Honda Coil and CDI unit with any MSD Components as severe damage may occur.
INSTALLATION
The MSD Enhancer Ignition is designed to mount between the rear frame rails in front of the tail light (Figure 1). Four mounting straps and foam strips are supplied with the kit to hold the ignition to the frame.
1. Hold the ignition in position between the rear frame rails and mark the location of the mounting straps. Wrap the supplied foam strips around these positions then install the mounting straps to the frame rails (Figure 1).
Figure 1 Installing the Mounting Straps.
2. Mount the Ignition with the base plate facing up to the straps using the supplied hardware as shown in Figures 2 and 3.
Figure 2 Mounting the Ignition Figure 3 Installing the Mounting Straps.
3. With the Ignition mounted, connect the two wiring harnesses and route them along the upper frame rail on the left side. Route the Black and Red wires toward the battery terminals.
DO NOT CONNECT THEM TO THE
BATTERY AT THIS TIME.
4. Locate the original 5-pin connector above the battery (it looks like a rectangular connector wrapped in electrical tape). Trace these wires about six inches forward. At that position,
Figure 4 Splicing the Pickup Wires.
MSD POWERSPORTS • 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
INSTALLATION INSTRUCTIONS 3 cut away the black sleeve to access the
Green/White and Blue/Yellow wires.
These are the pickup wires and need to be spliced (Figure 4) to be connected to the MSD Ignition.
5. Cut the Green/White and Blue/Yellow wires and strip the sleeve back to install the supplied bullet connectors. Using a good quality crimp tool (such as the MSD
Pro-Crimp Tool, PN 00-00-1515/PN 3505) and install the female bullet connectors to the wires going to the pickup. Install the male ends to the side that goes towards the 5-pin connector (Figure 5).
6. Connect the Blue MSD wire to the Blue/
Yellow Honda wire and Green MSD to the
Green/White Honda wire.
7. Continue routing the MSD harness along the upper frame rail to the coil. Disconnect and remove the original coil (Figure 6).
8. Mount the new Coil to the supplied bracket then mount the assembly. The
Black ground wire must be connected to the bracket’s mounting bolt (Figure 7).
9. Continue routing the remaining wires towards the front of the quad and locate the factory CDI control box under the front cover (Figure 7). Find the Black/
White wire from this box. Cut this wire and install a female bullet connector on the CDI side of the wire and a male on the switch side. The MSD White wire will connect to the male bullet connector.
The female side of this wire will not connect to anything (it is provided so the ignition can be returned to stock if ever desired).
10. Cut Black wire coming from Ignition switch and install the male bullet connection on the starter switch side and female bullet on ignition switch side. Attach the
MSD Black wire bullets to these two wires.
Figure 5 Installing the Bullet Connectors to the Pickup Wires.
Figure 6 Removing the Original Coil.
Figure 7 Installing the New Coil.
MSD POWERSPORTS • 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
4 INSTALLATION INSTRUCTIONS
11. Connect the Red MSD wire to the battery positive side of the starter solenoid (Figure 8).
12. Connect the Black wire to the common ground connection next to the battery (Figure 9).
13. Holeshot Wire: The Light Blue wire of the MSD is the Holeshot Control wire and will be connected to the clutch switch with the supplied Yellow/Blue wire connector splice. When this wire is grounded, the Holeshot rpm is active (see the Wiring Diagram in Figure 11). Unplug the
Yellow/Green wire in the clutch switch circuit and connect the MSD Yellow/Blue Y-splice. Next plug in the MSD Light Blue wire of the Y-splice to the MSD Light Blue holeshot wire.
Figure 8 Connecting the Main MSD Positive Wire.
Figure 9 Connecting the Main MSD Negative wire.
Figure 10 Main Wiring Diagram.
MSD POWERSPORTS • 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
INSTALLATION INSTRUCTIONS 5
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.
Default Positions:
Switch Bank 1
Max Timing +5° BTDC
S1=ON, S2=OFF, S3=ON
HS Retard S4=OFF
Max Speed Rev Limit 11,000 rpm
S5=ON, S6=OFF, S7=OFF, S8=ON
Switch Bank 2
Hole Shot Rev Limit 6,000 rpm
S1=OFF, S2=OFF, S3=ON, S4=ON
Full Timing RPM 2,000 rpm
S5=OFF, S6=OFF, S7=OFF, S8=OFF
This setup will give stock max timing of
27° BTDC at a lower speed of 2,000 rpm.
The timing can be increased to a maximum of 29°BTDC for a higher elevation or high octane fuel. The timing advance is set to reach full maximum advance timing at 2,000 rpm vs. 4,200 rpm stock curve for better low speed response. The MAX speed revlimiter is set for 11,000 rpm which is 1,975 rpm greater than the stock rev limiter. The
Holeshot is set up for 6,000 rpm and can be adjusted from 3,000 to 6,750 rpm.
Figure 11 Default Settings.
MSD POWERSPORTS • 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
6 INSTALLATION INSTRUCTIONS
Figure 12 Timing Range and Rev Limiters.
MSD POWERSPORTS • 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
INSTALLATION INSTRUCTIONS 7
TECH NOTES
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MSD POWERSPORTS • 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
8 INSTALLATION INSTRUCTIONS
TECH NOTES
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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 • 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 858-3365 • FAX (915) 858-3496
FRM26122 Revised 09/04 Printed In U.S.A.
