DIY 750 Total Loss Ignition
Electrical Box Removal Instructions
Disconnect negative wire from battery.
Remove red starter and battery wire from electrical box.
Remove electrical box (4) bolts.
Remove (2) bolts on top of electrical box holding wiring harness.
Remove (8) bolts on back side to open electrical box.
Unscrew (2) plastic nuts sealing wire harness and remove rubber grommets and plastic nuts from wires.
(The use of soap will ease removal of grommets)
Remove all electronics (coil, spark plug wires / CDI, voltage regulator) the only part left in the electrical box will be a starter relay and the heat slow system. it will have a red/yellow and black/yellow wires. it is not used with our system.
Electrical Box New Coil Installation
Top coil will mount on two protruding posts with spark plug post facing down.
Black wire from starter relay is mounted under top coil mounting bolt. Use OEM coil bolts.
Bottom coil will have two wing extensions. these will bolt into the bottom two protruding posts with spark pug wire facing up
Cut one spark plug wire 16″ long for top coil.
Cut one spark plug wire 21″ long for bottom coil.
Route the short plug wire through existing OEM hole using OEM grommet and plastic nut. ( short plug wire is routed through inside hole . long wire is routed though out side hole and is mounted to bottom of coil.)
the two coils are connected by the brown jumper lead included in the kit.
The 7-1/2″ orange wire is connected to the top coil screw terminal.
The 7-1/2″ black wire is connected to the bottom screw terminal.
Route the orange and black wires from the coils through the bottom hole.
install the new brain box in front left corner of ski. the hood seal has a flat spot between nose and the seal. drill two 1/4″ holes using the brain box as a template and mount it with the bolts included.
Re-seal electrical box with light coat of silicone on the O ring using the (8) bolts removed previously.
Mount the electrical box using the (4) bolts you removed previously. Replace bolts in same location. Reconnect bilge hoses.
Flywheel Cover Removal
Remove (7) flywheel cover bolts and cover.
Remove the (3) allen bolts holding the charging coils, @2) Phillips screws holing the wire harness retaining plate and rubber grommet and the (2) screws holding the trigger. 9all parts should be removed from flywheel cove including wire harness). Save the (7) hole grommets and retaining ring to be used later.
Mount the new stator with pick-up at 4 o’clock position. (final timing will be done with timing light)
Run the trigger wires trough the retaining plate and (7) hole grommet through the flywheel hole where previously removed use silicone to fill the extra holes.
If you don’t have a flywheel holder you can substitute the following: Rotate the crankshaft until #1 piston is TDC. Turn the flywheel 1/4 turn clockwise . using a 2 ft. piece of rope push 10″ of the rope into the spark pug hole. This will stop the crank shaft from rotating. during the flywheel bolt removal and insulation
Loosen flywheel nut and remove the flywheel using an appropriate flywheel puller (18mm bolt)
Inspect flywheel key for damage replace with new one if damaged.
If starter gear was removed install this before installing the flywheel
Install the flywheel key and new flywheel with washer included in kit and OEM bolt torqued to 72 ft. lbs.
Position a small amount of molding cal on the trigger
install the flywheel cover and crush the clay between the stator pickup and the flywheel . Remove flywheel cover and measure clay thickness with calipers.
The air gap between the flywheel and the trigger should be .080 to .100 if this is not correct use shims to achieve the measurement.
Install a dial indicator in the #1 spark Plug hole. Using your conversion chart determine how many thousandths before TDC is required for your application.
Rotate the flywheel until the #1 piston is TDC . thru the dial indicator to zero(0)
Rotate the flywheel counter-clockwise. your pre-determined thousandths before TDC . Using liquid paper mark your flywheel and center line though the flywheel cover hole and these lines should line up when timing light is aimed while engine is running 4000 to 6000 rpm
If you lines don’t line up remove your flywheel and re-adjust your stator to achieve the correct timing.