— CAUTION —
NO STRUCTURAL REPAIRS ARE PERMISSIBLE. REPLACE ALL ITEMS SHOWING WEAR, DAMAGE, OR THAT ARE NOT WITHIN SPECIFIED TOLERANCE.
ASSEMBLY OF MAGNETOS (REFER TO FIGURES 74-4 THRU 74-7.)
— CAUTION —
THE FOLLOWING MUST BE REPLACED AT OVERHAUL: CONDENSER, DISTRIBUTOR BLOCK AND GEAR, BEARING CAP ASSEMBLY, DOUBLE SEALED BEARING, COIL, IMPULSE COUPLING, OIL SEAL, CONTACT POINT KIT, AND ROTOR GEAR.  REFER TO SLICK PARTS LIST FOR PART NUMBERS.
1.  
Insert base plate (T-117) and adapter plate bushing (T-119) into base of T-125 assembly fixture. Assemble bearing cap assembly and ball bearing on rotor shaft. Place rotor shaft into base plate, threaded end down. (See Figure 74-6.) Using bearing assembly plug (T-101), turn T-screw down until both bearings are seated tightly against shoulder on rotor shaft. Remove base plate (T-117) and adapter plate bushing (T-l19).

2.  
Assemble bearing and rotor assembly into magneto frame and place magneto frame into T-125 assembly fixture.

3.  
Using rotor and frame assembling plug (T-102), turn T-screw down until bearing cap assembly bottoms in frame. (Refer to Figure 74-6.) Put T-151 cam and rotor plug on the end of the rotor shaft and turn T-screw until the shaft bottoms in magneto frame. Install bearing clamp on bearing cap assembly, install screw, and lock washer. Tighten to a torque of 20-24 inch-pounds.

4.  
Reverse magneto on T-125 assembly fixture so flange of magneto is facing up. (Refer to Figure 74-7.)

5.  
Lubricate oil seal with light grease and assemble seal over end of rotor shaft. Using oil seal assembling plug (T-103), turn T-screw to press seal flush with frame of magneto.

6.  
Assemble woodruff key into key slot of rotor shaft.

7.  
Install impulse coupling assembly and washer on shaft, and tighten nut. Tighten to a torque of 120 to 180 inch-pounds, so coupling is properly seated on taper shaft, and install cotter pin. Check to see coupling is free by snapping it through 3 or 4 times.

8.  
Place frame on T-125 assembly fixture. Insert coil into frame; make sure it is against the stops.  Insert coil wedges between bridge and frame.

9.  
Drive the two wedges tight, (use hammer and flat punch). Attach ground wire of coil to frame, (use screw and lock washer). Tighten to a torque of 20 inch-pounds.

10.
Check vertical portion of the high-tension lead of coil. Make sure it is flush with or up to 0.03125 of an inch below frame face.

74-10-00 Page 74-12 Issued: April 1, 1997
3H16

74-10-00 Page 74-13 Revised: February 28, 2002
— Note —
Wait until magneto is timed before installing gear, then install cotter pin.

11.
Assemble contact point kit on bearing cap assembly using screws from kit.   Insert cam in cam slot with screwdriver blade, position T-151 cam and rotor plug over it, and tap with light hammer. Drive cam all the way to bottom of cam slot. Apply M-1827 cam grease sparingly to each lobe of cam before assembly.

12.
To time magneto internally, place magneto on T-125 assembly fixture and make sure coupling lugs are in slots of index plate. Align magneto so that coil is at 12 o'clock.

13.
Insert T-150 "E" gap gauge between the pole laminations on the rotor shaft and the pole laminations in the frame. Locate the appropriate "L" or "R" timing slot (based on magneto rotation) on the rotor magnet head and insert the notched end of the T-150 "E" gap gauge. Rotate magneto frame (clockwise for left-hand rotation magnetos and counterclockwise for right-hand rotation magnetos) against pin which will line up rotor and cam for E gap position.

14.
Attach either red or green wire of timing light to bronze point terminal and black wire to frame of magneto. (Refer to Figure 74-8.) With a screwdriver, adjust points to just be opening when the frame is against the T-150 gauge. This gives a point gap of 0.008-0.012 inch. Secure points by tightening screws. Torque adjusting screw to 18-20 inch-pounds and pivot screw to 15-18 inch-pounds. Attach coil wire to vertical bronze male terminal of point assembly. Apply cam grease sparingly to each cam lobe.

15.
Assemble rotor gear onto rotor, making sure key slot of gear fits into cam slot of rotor. Tap with light hammer until gear bottoms on shaft.

16.
Assemble condenser into distributor housing, carefully rotating condenser wire in same direction as condenser is tightened in housing. Assemble distributor gear in distributor block, with L and R facing you. Assemble bearing bar to distributor block so open side of dust collector is toward air vent and hood. Assemble distributor block in distributor housing, with cut-away toward condenser. Use screws and lock washers. Tighten to a torque of 18-20 inch-pounds.
　
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