Usage:
1. Turn the crankshaft in the direction of the engine rotation until the magneto timing marks (1) are in alignment.
2. Identify and disconnect electrical cable (3). Mark and remove one wire (4).
3. Mark the location of the magneto housing for reference and remove two bolts (2) and washers. Remove the magneto (5) from the governor drive group.
NOTE: The following steps are for the installation of the magneto.
4. Put the magneto (5) in position on the governor drive group.
5. Install two bolts (2) and washers.
6. Install wire (4) and connect electrical cable (3).
7. Refer to the specification manual topic "Timing Advance Information" Magneto Timing for correct magneto timing procedure.
Disassemble Magneto
Start By:
a. remove magneto
1. Remove four screws that hold cover (1) to the intermediate housing (2) and unplug connector (3).
| NOTICE |
|---|
Put a mark for alignment on the connector halves. Hold both halves of the connector. Do not pull the wires to separate the connector. |
2. Remove timing cover (4), screw (5) and timing label (6).
3. Remove screws (7) and nut (8) for the diode.
4. Remove driven gear (9).
5. Tilt circuit board (10) away from the pick-up coils and unplug the wires from the pick-up coils at the circuit board pin connectors. Do not lose plastic brace when circuit board is moved away from pick-up coils.
| NOTICE |
|---|
Use needle nose pliers to unplug the receptacles at the pin connectors. Do not pull the wires to disconnect the pin connectors. |
6. Use tool (A) to give support to end cover (1) in a press.
7. Use tool (B), or rod of the same dimension, in a press to move distributor shaft, bearing and timer arm assembly (11) out of end cover (1).
8. Use tool (A) to hold timer arm assembly (11) so shaft bearing can be pressed out of aluminum hub in timer arm assembly (11).
9. Remove spring pin (12) and drive coupling (13).
| NOTICE |
|---|
Put identification on flange (14) and housing (15) so flange (14) can be installed in the same position. |
10. Remove flange (14) from front housing (15).
11. Give support to flange (14) with tool (A) in a press and use tool (C) to remove seal (16) from the flange.
12. Disconnect stator wires from clamp (18).
13. Remove three screws that hold intermediate housing (17) to stator and front housing (15) and remove intermediate housing (17). Use a soft hammer to separate intermediate housing (17) from the stator.
| NOTICE |
|---|
Intermediate housing (17) fits on a bearing rubber cover on the rotor assembly. |
| NOTICE |
|---|
Put a mark for alignment on stator (21) and front housing (15). |
14. Remove drive gear (19), bearing rubber cover (20) and stator (21).
15. Put front housing (15) in tool (A) in a press. Press the shaft and rotor assembly out of front housing (15).
| NOTICE |
|---|
Do not let the shaft and rotor assembly fall after it is clear of the bearing. |
16. Put front housing (15) on tool (A) in a press and use tool (C) to remove the bearing from the front housing.
17. Use tool (A) to hold bearing (22) in a press. Press shaft and rotor assembly (23) out of bearing (22).
| NOTICE |
|---|
Do not let the shaft and rotor assembly fall after it is clear of the bearing. |
18. Replace all parts contained in the repair kit.
19. Clean all parts and remove metal filings from the magnetic-rotor.
Assemble Magneto
1. Put spacer (2) in position on the drive gear end of shaft and rotor assembly (3).
2. Give support to the shaft and rotor assembly (3) with tool (A) in a press.
3. Use tool (B) to press bearing (1) against spacer (2).
4. Give support to front housing (4) with tool (A) in a press. Use tool (D) to install the bearing into front housing (4).
5. Use tool (A) in a press to hold the rotor of shaft and rotor assembly (3).
6. Use tool (C) with a 11.1125 mm (.4375 in) hardened washer to install front housing (4) and bearing onto the coupling end of the shaft and rotor assembly (3).
7. Before further assembly, check dimensions (X) and (Y) of the shaft and rotor and front housing.
8. Dimension (X) from the drive gear end of the bearing is 15.6 mm (.615 in). Be sure the rotor is against spacer (2).
9. Dimension (Y) from the coupling end of the shaft to the bearing is 38.7 mm (1.524 in).
10. Put stator (6) in position in front housing (4). Use the mark put on at disassembly for alignment reference. Do not damage the teflon wrapping.
11. Install bearing rubber cover (5) on bearing (1).
12. Install drive gear (7) on the shaft.
| NOTICE |
|---|
Put Vaseline petroleum jelly in the base for the bearing in intermediate housing (8). |
13. Put intermediate housing (8) in position on stator (6). Be sure the wires are on the same side as the flat base on the intermediate housing (8). Put wires in clamp (9).
14. Install three screws through intermediate housing (8), stator (6) into front housing (4). Tighten the screws evenly to bring the housing together over the stator.
| NOTICE |
|---|
Do not damage the teflon wrapping on stator (6). |
15. Put 9S3263 Sealant on the outside of seal (10) and use tool (D) to install seal (10) into flange (11). The lip of the seal faces out.
16. Install the gasket between flange (11) and front housing (4). Align the mark and install the four screws.
17. Install coupling (12) and spring pin (13).
18. Give support to end cover (16) in a press.
19. Use tool (E) and a press to install shaft and bearing (14) into its bore in the end cover. Be sure shaft and bearing is bottomed in its bore.
20. Support end of shaft (arrow) and use tool (E) and a press to install timer assembly (15) onto shaft (14).
21. Install timer assembly until dimension (Z) between the pick-arm and pick-up coil is 0.25 to 0.46 mm (.010 to .018 in)
22. The timer arm (15) must rotate freely. If there is interference between the timer arm and the pick-up coils or magnet, remove shaft and bearing (14) and timer arm from end cover (16).
23. Remove timer arm (15) from shaft and bearing (14).
24. Repeat Step 20. Dimension (Z) must not exceed 0.46 mm (.018 in).
25. Install gear (17) on timer arm (15).
26. Put circuit board (18) into position in end cover (16). Connect the wire receptacles to the circuit board pins. The wires are held in order by the wire guide.
27. Do not change the order of the wires. Be sure the pick-up coil wire receptacles seat all the way on the circuit board pins. Use American Pamcer Inc. No. 90204-1 Crimping Tool to crimp the receptacles.
28. Install the screws to hold circuit board (18) to end cover (16). Install the nut on the diode stud.
29. Install plastic brace (19).
30. Install shaft timing label (20) but do not tighten the screw.
31. Put timer arm (15) over the center of pick-up oil [(A) painted red].
32. Set the mark on the shaft timing label (20) between the "CCW" and "CW" marks and tighten the screw. Be sure the timing label is clean. Check Steps 30 and 31 again.
33. Install the timing cover and gasket.
34. Put the gasket in place on end cover (16).
35. Align the mark on connector (21) and engage the halves of the connector.
36. Guide the wiring into the intermediate housing (8) and engage end cover (16) onto the dowels on the intermediate housing (8). Install and tighten the screws that hold end cover (16).
End By:
a. install magneto