Info

Condenser and Bracket

Fulcrum Pin Snap Ring

Set of Points

Breaker Arm Wick

Contact Support Screw and Washer

Contact Support Screw Washer

Contact Support Screw Washer

Cam Wick and Holder

Bearing Support Screw (4)

Safety Gap (To late 1964)

Bearing Support

Rotor Drive (1) Grease Retainer Washer (1)

Rotor Cam End Bearing

Rotor Drive Gear Pin

Rotor Drive Gear

Drive Housing Screw (4)

Drive Housing

O-Ring Washer (Late 1965 to early 1968) O-Ring (Late 1965 to early 1968) Seal (Late 1968) Drive Housing BushingRotor Drive End Seal Outer Washer Rotor Drive End Seal Rotor Drive End Shaft Snap Ring Rotor Drive End Bearing Snap Ring Rotor Drive End Bearing-Coil Bridge Set Screw (2) Coil

Coil Lead Spring (2) Rotor

Primary Ground Switch Terminal

Ground Switch Terminal Wire

Vent Cover Screw (2)

Vent Cover Washer (2)

Vent Cover (2)

Vent Screen (2)

Housing-

Adapter to Magneto Bolt (2) Adapter to Magneto Bolt Nut (2) Adapter Screw (2) Adapter (1964 & earlier) Inner Adapter Plate (1965) Outer Adapter Plate (1965) Adapter to Crankcase Gasket (Early 1965) Magneto to Crankcase Oil Seal Ring-Ground Switch Lock Insulating Block Retainer Clip Switch Lock Body SpringBall

Insulating Block Terminal Screw

Ground Switch Lock Wire

Tachometer Drive Retaining Pin Clip

Tachometer Drive Retaining Pin

Tachometer Drive Cable

Tachometer Drive Gear

Tachometer Drive Gear Thrust Washer

Tachometer Drive Cable O-Ring-

Control Arm (1965)

Cotter Pin (1965)

Spring (1965)

Washer (1965)

Swivel Block (1965)

Set Screw (1965 to early 1967)

Set Screw Spring (1965 to early 1967)

Roll Pin (Late 1967)

Figure 5F-8. Magneto

Insert rotor shaft into gearease. Install magneto on adapter plate and attach with bolts (44) and nuts (45). On magnetos having manual retard, install magneto control arm (63) before replacing mounting bolt nuts.

Adjust ignition timing. See "Timing Ignition."

On manual retard magneto install control wire (21) through swivel blocks (22) when handlebar grip control and magneto are in fully advanced position. Turn handlebar grip control to full retard then to advance position and check to see that magneto has returned to fully advanced position against screw stop. Readjust control wire in swivel block if necessary.

INSPECTION AND REPLACEMENT OF PARTS (Fig. 5F-6)

Inspect circuit breaker points (4). Normally, point contact surfaces should appear clean, dull gray, and slightly rough. If contact points are dirty, they may be cleaned with a strip of hard surface paper saturated with clean white gasoline. If points are pitted, burned or worn badly, they should be replaced.

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

To replace a set of circuit breaker points remove screw (20). Remove fulcrum pin snap ring and lift circuit breaker lever from pivot stud. Remove screws (10 and 11), cam wick holder and circuit breaker stationary contact.

Install new points in reverse order of disassembly. 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. 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. The cam oiler felt (13), if dry or hard, should be replaced by a new factory- impregnated wick.

The condenser (3) 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.

If the coil (1) is suspected of being defective replace with a proven new coil and note whether engine performance has improved.

DISASSEMBLING MAGNETO (Fig. 5F-8)

Remove four end cap screws (1), end cap (2) and end cap gasket (3). Pull the two spark plug cables (4)

from the end cap (2). The spark plug cable terminal (5) may be removed by sliding the cable protector (6) up the spark plug cable (4) and prying it loose with a screwdriver.

Remove condenser mounting screw (7), condenser mounting washer (8) and breaker arm tsrminsil scrsw (9A). Remove condenser and bracket (10).

Pry the fulcrum pin snap ring (li) loose from the fulcrum pin and slip off the breaker arm half of the set of points (12). Remove the breaker arm wick (13) from the breaker arm.

Remove contact support screws (14 and 9), contact support locking screw washer (16 and 15), cam wick and holder (17) and stationary half of set of points

Remove the four bearing support screws (18), safety gap (19) (if used) and bearing support (20). Pry rotor drive and grease retainer washer (21) from bearing support (20) and remove rotor cam end bearing (22). File one end of the rotor drive gear pin (23) and punch it out with a punch. Pull rotor drive gear (24) from shaft. Remove the four drive housing screws (25) and slip the drive housing (26) off the shaft. Remove O-ring retainer washer (26A) and O-ring (26B). If necessary remove the drive housing bushing (27) from the inside of the drive housing (26).

Remove rotor drive end seal outer washer (28), rotor drive end seal (29) and rotor drive and grease retainer washer (21). Force rotor drive end shaft snap ring (30) from rotor shaft.

Remove rotor (36) from housing (43).

Remove rotor drive end bearing snap ring (31) and rotor drive end bearing (32).

Remove the two coil bridge set screws (33) and coil (34). Remove the two coil lead springs (35) from coil

Remove primary ground switch terminal (37) and ground switch terminal wire (38).

Remove the two vent cover screws (39), vent cover washers (40), vent covers (41) and vent screen (42).

ASSEMBLING MAGNETO (Fig. 5F-8)

Assemble magneto in reverse order of disassembly.

Do not tap or hammer rotor into housing. Such jarring could destroy the magnetism thus reducing the current generating capabilities of the magneto.

Install magneto and reconnect wires.

GROUND SWITCH LOCK (Fig. 5F-8)

To remove ground switch lock proceed as follows: remove end cap (2). Between the ground switch lock insulating block (50) and the magneto housing (43) there is a retainer clip (51) on the lock body (52). Using a piece of metal or knife, depress retainer clip and at the same time, using key in switch as a lever, pull key out to exert pressure and also turn slightly at same time to pull switch lock out of magneto housing. Be careful not to lose ground lock spring (53) and ground lock ball (54) which are found in ground switch insulating block screw (55) hole.

To reassemble switch lock, insert ground switch lock into magneto housing making sure that retainer clip is on top of inside switch housing. Take knife and depress body retainer clip (51) and push ground lock switch into magneto housing so retainer clip engages housing. Loosen condenser screw (7) to facilitate removal of ground switch insulating block screw.

Remove ground switch insulating block screw (55) and ground switch wire (56). Insert ground lock ball and then ground lock spring. Replace ground switch insulating block wire and screw, and tighten condenser screw.

TACHOMETER (Special Equipment)

Grease tachometer drive gears at base of magneto, with All-Purpose grease every 2000 miles. Remove clip (57) from retaining pin (58) to pull out drive gear and cable (59). Fill housing hole with grease. Also remove drive gear (60) with thrust washer (61) from cable (59) and fill casing hole with grease.

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