Usage:
1. Remove the magneto from the test bench.
2. Remove the four screws (1) from magneto cover (2).
3. Remove cover (2) by lightly hitting the cover with a soft or rubber hammer.
4. Remove two screws (3) from the top of the distribution board. Put a screwdriver between the heat sink section and the pulser coil housing. Pull the screwdriver to remove the heat sink and end cap section. Remove the two screws at the bottom of the distribution board.
NOTE: It may be necessary to lightly hit the end cap section with a soft hammer to break the sections loose.
5. Remove the end cap section from the heat sink.
6. Remove the two screws (14) that hold the diode to the heat sink (12). Increase the temperature of the solder which holds the red wire to the terminal on the diode. When the solder becomes liquid, remove the wire.
7. When the diode is still warm, put a knife between the heat sink and diode. Twist the knife to remove the diode.
8. Install the zener diode on the heat sink and fill the terminal holes in the heat sink with 5M2941 Epoxy Cement. Connect the red lead to the top terminal of the new zener diode with solder.
NOTE: Inspect the ends of the two screws that hold the diode to the heat sink. If the ends are sharp and are extra long, they may cause damage to the pulser coil wires. Put 5M2941 Epoxy Cement over the ends of the screws until they are smooth.
9. Do the FAILURE ANALYSIS again to be sure the problems have been corrected.