And Later Sportster And 1964 And Later Servicar

On earlier models, remove nuts and washer (20A) which secure base to stem. Remove base (10B) exposing two screws and washers (21) securing shaft and housing assembly to gear case cover. Remove screws (21) and lift shaft and housing from gear case cover. On 1966 automatic advance type, remove stem clamp bolts (35) and clamp (34A) to free entire circuit breaker from crankcase.

inspection and replacement of parts (Fig. PF-1, 5F-1A, 5F-1B and 5F-2)

Using cloth with clean white gasoline, wipe circuit breaker clean and inspect parts.

Inspect circuit breaker contact points (5 and 5A). If lever fiber (2) is badly worn, replace points. Points that are burned or pitted should be replaced or dressed with a clean, fine-cut contact point file. Do not attempt to remove all roughness nor dress point surfaces down smooth; merely remove scale or dirt. Contact point file should not be used on other metal and should not be allowed to become greasy or dirty. Never use emery cloth or sandpaper to clean points, since particles will embed themselves and cause arcing and rapid burning of points.

Circuit breaker points should be replaced, if contact point pressure is not within prescribed limits of 14 to 18 oz. Check pressure with a spring gauge. The scale should be hooked to the breaker lever at an angle of 90 degrees with the point surface and reading taken just as points break. Excessive pressure Causes rapid wear of fiber block, cam, and contact point. Insufficient pressure will permit high speed point bounce which will, in turn, cause arcing and burning of the points and missing of the engine.

Point faces must seat squarely against each other. If bent, square up by bending contact plate.

To replace a set of circuit breaker points, loosen screw (11) and slip condenser wire and connection from screw. Lift circuit breaker lever (12) from screw (11) and pivot stud (13). Remove screw (6) and circuit breaker contact point and support (14). Install new points in reverse order of disassembly. Position circuit breaker lever (12), lever notch registered with screw (11), between brass washer and condenser wire end. Be sure point faces seat squarely against each other. Adjust point gap as previously described in "Adjusting Circuit Breaker Points."

Lubricate breaker cam with a trace of grease when points are replaced or every 5000 miles. Also remove cam and lubricate shaft with very light grease Delco Remy No. 1960954 or equivalent. Replace cam in correct position.

Check circuit breaker advance flyweight action by moving cam in direction required to advance weights to their fully extended position. Then release the cam and see if springs return to the fully retarded position. Correct causes for faulty action by cleaning and lubricating shaft, cam and flyweights and replacing weak springs.

Be extremely careful to avoid excessive lubrication. If too much grease is used, the excess is apt to get on the contact points and cause them to burn.

For maximum operating efficiency it is recommended practice to replace circuit breaker points when pitted, burned or worn excessively.

The condenser (4) is a relatively long life part and will not require frequent replacement. However, if the condenser is suspected of being defective simply replace with a proven new condenser and note whether engine performance is improved. A condenser that is defective will have either an open or short circuit. An open circuit will be evident by excessive arcing at breaker contact points and a shorted circuit will have no noticeable spark at the contact points.

Examine the circuit breaker base pivot stud (13) for wear or damaged condition. Try circuit breaker base (10, 10A or 10B) Fig. 5F-2 on stem, (22, 22A, 22B or 22C) for free turning, but not loose fit. If base has too much clearance on stem, the circuit breaker point gap will vary as the base is shifted for spark control. If base is found excessively worn or damaged in any way, renew it.

Examine the coil to circuit breaker low tension wire (12 or 12A, Fig. 5F-2) for brittle or cracked insulation and broken strands and replace if defective. Inspect circuit breaker wire stud insulator (15) and fiber washer (13) for brittle or cracked condition. Unless inspection shows insulation defective, it is not necessary to remove stud, insulator and washers.

Examine cam advance mechanism on automatic advance circuit breakers to see that flyweights (26) move outward freely and springs (27) return them inward against stops. Check for looseness of cam (24) on spindle (29B or 29C) and wear on sides of flyweight (26) ears which engage slots in cam. Check springs (27) and replace if stretched or distorted.

To disassemble mechanism pry clips (25) from grooves in pivot pins on stem plate (29B or 29C). Inspect teeth or worm gear (31) for excessive wear and damage. Check the amount of end play and side play of shaft (29, 29A, 29B or 29C) in stem. End play in excess of .008 in. or excessive side play of shaft in stem bushings will affect ignition timing and also allow oil from cam gear base to enter breaker assembly base to contaminate ignition points.

If renewal of shaft or stem parts is necessary remove pin (30) from gear and lift or press circuit breaker cam shaft from gear. Withdraw cam shaft from base. If bushings have excessive wear, timer stem assembly can be replaced or stem assembly can be rebushed by drifting out old bushings and installing new bushings. New bushings should require no reaming. When reassembling gear and breaker cam shaft use spacer washer (.062 thick), (.066 thick), (.072 thick) or (.076 thick) to obtain a .001 to .007 in. shaft end play.

When assembling circuit breaker shaft in breaker stem, always secure gear and spacer washer to shaft with new steel pin riveted in place. Rotate shaft to be sure it is free in stem.

installing circuit breaker

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