Usage:
NOTE: Inspect each part as it is removed for wear or broken pieces.
1. Remove the four screws (1) from the magneto cover and remove cover (2).
2. Remove the two screws (3) from the top of the distribution board. Put a screwdriver between the heat sink section and the pulser coil housing. Twist the screwdriver to remove the heat sink and end cap section.
NOTE: It may be necessary to lightly hit the end cap section with a soft hammer.
3. Remove four screws (4) from plate (5), remove plate (5).
4. Remove nut (6) and the washer which fasten the pulser to the shaft. Remove pulser (7).
| NOTICE |
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Use extra care when removing nut (6). Do not use the drive coupling to keep the pulser shaft from turning. Damage to the fiber gear may result. Put a large nut over a pick-up on the pulser coil. Turn the drive coupling until the pulser rotor comes in contact with the nut. Remove nut (6). |
5. Remove two screws (8) from the center of pulser coil (9). Disconnect the two white and the two gray wires from terminals (B-1), (B-2), (B-3) and (B-4). Remove the nylon strap that holds the wires. Remove two screws (8) from the lower edge of the pulser coil. Remove the pulser coil.
NOTE: The electronic section of the magneto can be removed at this time.
6. Remove four screws (10) which hold pulser coil housing (11) to the drive end of the magneto. Remove housing (11).
7. Remove three screws (12) from drive assembly (13).
8. Remove nut (14) which fastens drive coupling (15) to the shaft. Remove the drive coupling from the shaft. Remove the key from the shaft.
9. Remove washer (16), seal (17) and washer (16) from the shaft. Remove the snap ring from the shaft.
10. Remove the drive assembly from housing (18).
11. Remove the magnetic rotor (19) from the bearing support (20).
12. Remove the distributor shaft spacer. Remove the distributor gear (21) from the bearing support.
NOTE: The distributor gear must be tight on the hub. If the gear can turn on the hub, the timing of the magneto will not always be correct.
13. Remove the two snap rings (22) which hold the bearings in the bearing support. Remove the bearings from the bearing support.
1. Install the bearing (2) in the housing (1).
2. Install the bearing retainer (3) in the housing. Install the screw (4) that fastens the bearing retainer in the housing.
On 8 and 12 cylinder units install the snap ring.
3. Install coil (5) in the housing. Put two wedges (6) in position in the housing. Install screws (7) that fasten the wedges to the housing.
4. Install bearing (8) for the distributor gear in bearing support (9). Install bearing (10) for the magnetic rotor in the bearing support. Install the two snap rings that hold the bearings in the bearing support.
5. Install distributor gear (12) in the bearing support.
6. Put the mark (the drilled hole), on gear of the magnetic rotor (11) in alignment, with the correct mark of the distributor gear. A is counterclockwise, C is clockwise rotation of magneto. Install the magnetic rotor in the bearing support.
7. Install drive assembly (13) in the housing.
8. Install the three screws (14) in the bearing support.
NOTE: Be sure the drive assembly is in the center of the housing when tightening the screws.
9. Install the four screws (15) that fasten the pulser coil housing (16) to the drive end of the magneto.
10. Install the snap ring (17) to the shaft.
11. Install washer (19), seal (18) and washer (19) on the shaft. Put punch marks at three places around the lip of the housing to fasten the seal in the housing. Install the key to the shaft.
12. Install the drive coupling (20) on the magneto drive shaft (21). Install the nut that fastens the drive coupling to the shaft.
13. Install the pulser coil (23) in the pulser coil housing (22). Install the two screws (24) in the center of the pulser coil. Install the two screws in the lower edge of the pulser coil.
14. Install pulser rotor (25) to the shaft. (For magnetos that operate in the clockwise direction, the mark C on the rotor must be facing out, the mark A is for counterclockwise magnetos). Install the nut and washer that hold the pulser to the shaft.
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Tighten the nut to a torque of 12 ± 1 lb. ft. (1.6 ± .1 mkg). |
15. Install the plate (26) in the pulser coil housing (22). Install four screws that fasten the plate to the pulser coil housing.
16. Connect the wires as shown in the WIRING DIAGRAMS and assemble the magneto. Test the magneto as shown in the FAILURE ANALYSIS to be sure that no other problems exist and that the timing is correct.