MSD Pulse Ignition For Harley-Davidson
MSD Pulse Ignition For Harley-Davidson
PN 42211
IMPORTANT: Read these instructions before attempting the installation! It is also recommended to
have your bikes Service Manual available during the installation.
Parts Included In This Kit
1 MSD Pulse Ignition, PN 42211
1 Ignition Coil Pack, PN 43952
2 Super Conductor Spark Plug Wires,
PN 32019
1 Trigger Pickup & Rotor Assembly, PN 42315
WARNING: During installation, disconnect the battery cables. When disconnecting the battery,
always remove the negative cable first and install it last.
Note: The optional MSD Pulse breakerless distributor must be installed on Panhead, Knucklehead
or early-model Shovelhead V-Twins equipped with a distributor.
MOUNTING
The original ignition module may be removed or left in place. If it is left on the bike, disconnect all
of the connections to avoid interference with the MSD Pulse.
The MSD Pulse Ignition can be mounted in any position as long as it is kept away from direct
engine heat sources. MSD offers three unique flex mount kits that are available for different diameter
down tubes; PN 4393 (1" 1 1/16"), PN 43931 (1 1/2" 1 9/32") and PN 43932 (1 7/16" 1 17/32").
If you are going to make a custom mount, remember to:
Make it easy to access the programming switches.
Select a location that will not interfere with airflow to the front cylinder.
Ensure the location allows for the upward/rearward movement of the fender/wheel as the fork
compresses and does not interfere with steering clearance.
MOUNTING COILS
Remove the existing coil assembly, and then install the MSD dual coil pack/bracket to the frame
using the existing fasteners.
Note: On some applications, such as the Sportster, the MSD coil mount may require modification
to clear the gas tank. Never modify the black coil assemblies.
Harley-Davidson is a Registered Trademark of Harley-Davidson Motor Company.
MSD POWERSPORTS
1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 (915) 858-3365 FAX (915) 858-3496
INSTALLATION INSTRUCTIONS
SPORTSTER MODELS
1. On Sportsters, the wire access port must be
enlarged. Use a 9/32" drill bit to enlarge the wire
port.
2. Remove the wire harness clamp of the pickup
assembly and route the wires through the port.
3. Mount the MSD pickup plate inside the housing
(Figure 2). Note the adjusting notch on the edge of
the plate. This notch must be located over the cast
notch inside the housing (about the 11 oclock
position as you face the housing). The shorter of the
two sensors will be approximately in the 9 oclock
Figure1 Installing the MSD Pickup Assembly.
position.
4. Install the hold-down/standoff screws with flat
washers until they are snug - do not
tighten at this time (Figure 3).
3. Put the MSD rotor in place on the end of
the camshaft. The locating pin in the rotor
bore must align with the groove in the
cam. Do not force the rotor on the
camshaft! Push the rotor into place until
it is tightly against the end of the cam then
snug the retaining screw.
4. Check the distance from the outer surface
of the pickup plate to the end of the
installed rotor (Figure 4). If necessary, add
shims until the measured rotor height is
9/16" (+/- 1/32").
5. When the rotor height has been verified,
Figure 2 Pickup Position for Sportsters.
remove the retaining screw, place a drop
of Red Loctite on the threads and reinstall the screw to the factory recommended torque.
Note: On Sportsters, ensure that the loose pickup wires are clear of the rotor. Apply a small bead
of silicone to the wires to secure them.
MSD POWERSPORTS
1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 (915) 858-3365 FAX (915) 858-3496
INSTALLATION INSTRUCTIONS
NOTES:
1. (2) #8 WASHERS AND (1) 2.00" CAP SCREW SUPPLIED
WITH THIS PICKUP ASSEMBLY.
2. APPLY A SMALL DROP OF LOCTITE ON THE TIP OF THE
2.00" SCREW BEFORE FINAL INSTALLATION.
3. COVER SCREW LENGTH SHOULD BE LONG ENOUGH
TO ENGAGE INSIDE COVER BUT NOT PROTRUDE
THROUGH TO PICKUPS.
Note: If shims are used, make sure the rotor runs true. The shims may ride on the cam shoulder
radius if not properly installed.
6. The epoxy-covered magnet in the outer edge of the rotor should align just to the left of the slight
bulge on the inner surface of the upper pickup. If the alignment is not correct, the engine may
have been rotated from top-dead-center or the pickup plate is improperly installed. Verify this
alignment before proceeding. The housing cover should not be reinstalled until the timing
procedures are completed.
Before making any connections, check the following:
Verify that all wire harnesses are routed away from exhaust heat and sharp edges.
Ensure at least one inch separation between the coil harness and the pickup harness to reduce
electrical interference.
Leave some slack in the wire harnesses to accommodate engine and road vibration.
It is not recommended to extend or shorten the coil or pickup harnesses.
WARNING: Do not connect the negative (-) battery wire until the entire installation is complete.
MSD POWERSPORTS
1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 (915) 858-3365 FAX (915) 858-3496
INSTALLATION INSTRUCTIONS
WIRING
RED
BLACK
VIOLET
LIGHT BLUE
Two step rev limiter. When connected to ground, the two step rpm limit will
be active.
This terminal provides a standard tach signal.
TACH
TERMINAL
COIL
HARNESS
PICKUP
HARNESS
This is the longer 4-wire harness with two wires tagged Front Cyl. (for the
front cylinder) and the other two marked Rear Cyl.
This is the short 4-wire harness that connects to the MSD pickup assembly.
MSD POWERSPORTS
1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 (915) 858-3365 FAX (915) 858-3496
INSTALLATION INSTRUCTIONS
MSD POWERSPORTS
1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 (915) 858-3365 FAX (915) 858-3496
INSTALLATION INSTRUCTIONS
OPERATION
The MSD Pulse produces the computer-generated timing curve shown in Figure 7. Several
programming options are available to tune the ignition to your application. There are two switch
assemblies behind the aluminum base plate on the back of the MSD unit where programming
changes are made (Figure 8).
The MSD Pulse is programmed at the factory for operation on most engines. It is recommended to
install and run the MSD before making any adjustments. Figure 8 shows the factory settings.
Sportster timing will typically be 30 or less. Big Twin 36 or less, max timing BTDC.
1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 (915) 858-3365 FAX (915) 858-3496
INSTALLATION INSTRUCTIONS
MSD POWERSPORTS
1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 (915) 858-3365 FAX (915) 858-3496
INSTALLATION INSTRUCTIONS
The basic advance curve is always provided by the MSD Pulse, except when the VOES detects low
vacuum conditions in the manifold. A low vacuum signal causes the micro-processor to ramp to the
VOES curve over 1/2-second. When the VOES turns off the timing ramps to the max timing in one
second.
Note: Figure 7 on page 6 shows an example of the basic advance curve with a 4,000 rpm VOES curve.
1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 (915) 858-3365 FAX (915) 858-3496
INSTALLATION INSTRUCTIONS
MSD POWERSPORTS
1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 (915) 858-3365 FAX (915) 858-3496
10
INSTALLATION INSTRUCTIONS
TROUBLESHOOTING
INOPERATIVE TACHOMETER
The MSD Pulse delivers a conventional 12-13 volt square wave signal that is compatible with most
factory tachometers. Some aftermarket tachometers require a high voltage spike. If the tachometer
does not operate properly, an MSD PN 8920 Tach Adaptor should be used to provide a suitable
signal.
CHECK WIRING
Check wiring routing and connections.
Make sure all of the terminals and pins are crimped tightly and are fully seated in the connectors.
Confirm all of the connections with the wiring diagram in the installation instructions.
If any wires or connections have been modified or shortened, use an ohm meter to confirm
continuity through the connectors.
1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 (915) 858-3365 FAX (915) 858-3496
INSTALLATION INSTRUCTIONS
11
3. Using a jumper wire (a straightened paper clip works well), link the terminal of the black wire in
the MSD connector to the terminal of the white wire in the pickup connector.
4. Attach a similar jumper wire to the terminal of the Blue wire in the pickup connector and join it to
the first paper clip.
5. Turn the ignition switch On and separate the jumpers. A spark should jump from one of the
spark plugs.
6. Turn the ignition switch Off and reverse the connection. Link the terminal of Black wire in MSD
connector to the terminal of the Blue wire in the pickup connector. Attach the second jumper to
the terminal of the White wire in the pickup connector.
7. Turn the ignition switch On and separate the jumpers. A spark should jump from the other spark
plug.
If both the plugs fired, the MSD and the Coils are working properly and the corresponding
pickup(s) is probably at fault.
If one or both plugs did not fire, check the operation of the Coils.
COIL TEST
If the ignition is receiving a trigger signal from the pickups, but failed the spark test on one or both
cylinders, the resistance of the coils should be checked.
1. Disconnect the negative battery cable.
2. Disconnect the coil connector harness.
3. To check the primary resistance: Connect the ohm meter to the two terminals of the Front Coil.
Get a reading, and then connect the meter to the terminals of the Rear coil. The primary resistance
should be less than 0.5 ohm.
4. To check the secondary resistance: Remove the plug wires from the coils and connect the ohm
meter to the plug wire terminal and the corresponding primary coil terminal at the 4-pin connector.
The resistance should be between 1.5K 2K ohms.
5. If the coil(s) is out of specification, swap it with a known good coil and test for spark again. If only
one could fail, follow the proceeding procedure.
If an ohm meter is not available and only one of the plugs sparked in the original coil:
1. Turn the ignition switch off and disconnect the coil harness of the MSD amplifier from the coilpack harness.
2. Remove the orange lock plug from the open end of the connector on the coil-pack harness.
This plug is firmly locked in place and requires a hook-like tool between the edge of the plug and
the body of the plug. Note: It is possible to make a suitable
tool from a ten-penny nail. Grind or file the head of the nail
away until there is about a 0.100-inch wide hook left then
bend the tip over 90 (Figure 11).
3. Turn the hook under the edge of the plug and pull it free.
Push the gray tab and pull the pins out of the sockets in the
back of the connector.
4. Carefully swap both pins of each coil circuit to the
corresponding positions of the other coil. Be certain to
maintain the wire pairings (Black to Brown and Orange to
Orange/Green).
5. Re-assemble the connector with the swapped wiring and
check for spark.
If the same plug fails during each test, the coil is at fault
and requires replacement.
Figure11 Custom Wire Removal Tool.
If the opposite plug fails during the test, the ignition or
pickup is at fault.
MSD POWERSPORTS
1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 (915) 858-3365 FAX (915) 858-3496
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
FRM26218
1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 (915) 858-3365 FAX (915) 858-3496
Created 09/04
Printed In U.S.A.