Servicing Circuit Breaker and Base Assembly

(Reier to Illus. 68 and 69)

Note: 1946 and earlier model circuit breaker shown in Illus. 68 and 69 differs from 1947 model circuit breaker only as regards advance and retard lever. See paragraph 8, under "Ignition Circuit Breaker and Flywheel Timing Mark," Page 79.

Circuit breaker base can be disassembled for replacement of base, circuit breaker shaft and circuit breaker shaft gear.

Circuit breaker head mounts the circuit breaker lever, adjustable contact point and condenser which are readily accessible (on or off motorcycle) for adjustment and for replacement when circuit breaker cover is removed.

To disassemble base, remove the pin from gear and drift or press circuit breaker cam shaft out of gear. Withdraw shaft from base. A steel spacer washer is located between gear and base stem.

To disassemble circuit breaker head, remove nuts from condenser and terminal binding post to free the brass terminal strip. Remove breaker lever spring and lift breaker lever from its insulated pivot stud. Remove the two lock screws and plate, and adjustable contact point assembly is then free for removal. Remove condenser mounting screw and washer—this screw also grounds condenser to circuit breaker head.

If inspection shows it to be necessary to replace the low tension wire (coil to circuit breaker) simply remove terminal nut and washer and remove wire.

Unless inspection shows circuit breaker head insulated terminal is in bad condition or insulation is defective it is not necessary to remove this part.

Clean all parts and inspect for good condition and signs of wear. The cricuit breaker lever pivot stud insulation should be inspected and if found broken or cracked, replace circuit breaker head. The condenser may be tested on a condenser tester, although actual operation on engine is the surest, most dependable test.

Try circuit breaker head on base for a free turning, but not loose fit. If head has too much clearance on base, the circuit breaker point gap will vary as the head is shifted for spark control.

Replace any worn and/or damaged parts that will affect operation of circuit breaker as a whole.

Reassemble in reverse order of disassembly. When assembling circuit breaker shaft in circuit breaker base, select a steel washer (between shaft gear and base) that will give a free running fit to .008" endplay. Endplay in excess of .008" will affect ignition timing. Secure shaft gear to shaft with new steel pin riveted in place.

OJi.V. Models: When assembling circuit breaker complete for installation, make sure that low tension wire is allowed enough slack within circuit breaker head to be free for full advance and retard movement.

All Models: Circuit breaker points that are burned or pitted should be renewed or dressed with a clean fine-cut contact point file. The file should not be used on other metals and should not be allowed to become greasy or dirty. Never use emery cloth to clean points. Contact surfaces, after considerable use, may not appear bright and smooth; but this is not necessarily an indication that they are not functioning satisfactorily.,: .i f,... ; i^.,

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

Point gap with breaker lever fibre on highest point of cam, should be .022". Wrong cap affects ignition timing. Adjust by loosening the two lock screws and shifting adjustable contact plate. Measure gap with accurate thickness gauge before retightening lock screws and recheck gap after tightening lock screws. Note: Final checking and readjusting of point gap must be made after circuit breaker head is installed on base. See "Installing Circuit Breaker and Timing Ignition (OJi.V. Engine)", Page 81, or

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