X42003elec - 2012 04 10 PDF
X42003elec - 2012 04 10 PDF
X42003elec - 2012 04 10 PDF
High Tension
Magneto
SERVICE
SUPPORT
MANUAL
Available exclusively from the publisher: P.O. Box 90, Mobile, AL 36601
Copyright© 2011 -2012Continental Motors, Inc. All rights reserved. This material may not be reprinted, republished, broadcast, or otherwise
altered without the publisher's written permission. This manual is provided without express, statutory, or implied warranties. The publisher will
not be held liable for any damages caused by or alleged to be caused by use, misuse, abuse, or misinterpretation of the contents. Content is
subject to change without notice. Other products and companies mentioned herein may be trademarks of the respective owners.
Illustration
Number
Indexed Part
names
Itemized List
of Effective
Pages
Internet: http://continentalmotors.aero.
4. Disassembly
4-1. General ...................................................................................................... 4-1
4-2. Detailed Disassembly Procedures ............................................................. 4-1
4-2.1. Initial Inspection Disassembly ............................................................................4-1
4-2.2. General Overhaul Disassembly ...........................................................................4-2
4-2.3. Drive Plate and Front End Hardware Disassembly.............................................4-2
4-2.4. Impulse Coupling Disassembly...........................................................................4-2
4-2.5. Rotating Magnet Disassembly ............................................................................4-5
4-2.6. Bearing Removal.................................................................................................4-5
4-2.7. Spur Gear and Bearing Bushing Removal ..........................................................4-6
4-3. Harness Disassembly ................................................................................ 4-7
5. Cleaning
5-1. General ...................................................................................................... 5-1
5-2. Detailed Magneto Cleaning Procedures.................................................... 5-1
6. Periodic Maintenance
6-1. General...................................................................................................... 6-1
6-2. Detailed Maintenance Procedures ............................................................ 6-2
6-2.1. Contact Assembly Inspection.............................................................................. 6-2
6-2.2. Impulse Coupling Inspection .............................................................................. 6-4
6-2.3. 500 Hour Inspection............................................................................................ 6-8
7. General Overhaul
7-1. General...................................................................................................... 7-1
7-2. Detailed Overhaul Procedures .................................................................. 7-1
7-2.1. Magneto Disassembly ......................................................................................... 7-1
7-2.2. Distributor Gear Inspection................................................................................. 7-2
7-2.3. Breaker Cam Inspection...................................................................................... 7-3
7-2.4. Distributor Block Inspection............................................................................... 7-3
7-2.5. Capacitor Inspection ........................................................................................... 7-7
7-2.6. Coil and Clamp Inspection.................................................................................. 7-8
7-2.7. Impulse Coupling and Related Component Inspection....................................... 7-8
7-2.8. Magneto Housings and Cover Inspection ......................................................... 7-11
7-2.9. Rotating Magnet Inspection .............................................................................. 7-12
7-2.10. Drive Bushing, Drive Plate and Washer Inspection.......................................... 7-12
7-2.11. Magneto Assembly ........................................................................................... 7-12
7-2.12. Magneto Post Overhaul Testing ........................................................................ 7-12
7-3. Harness Overhaul.................................................................................... 7-12
8. Repair
8-1. General...................................................................................................... 8-1
8-2. Detailed Repair Procedures ...................................................................... 8-1
8-2.1. Coil Lead Repair ................................................................................................. 8-1
8-2.2. Threaded Hole Repair ......................................................................................... 8-2
9. Assembly
9-1. General...................................................................................................... 9-1
9-2. Detailed Assembly Procedures ................................................................. 9-2
9-2.1. Coil Installation................................................................................................... 9-2
9-2.1.1. D-3000 Series Magneto Coil Installation.......................................... 9-2
9-2.1.2. D-2000 Series Magneto Coil Installation.......................................... 9-4
9-2.2. Assemble Gear and Bushing on Rotation Magnet .............................................. 9-6
9-2.3. Install Bearing and Magnet in Housing .............................................................. 9-7
9-2.4. Distributor Block Assembly................................................................................ 9-8
9-2.5. Distributor Block and Gear Assembly ................................................................ 9-9
9-2.6. Distributor Block and Gear Installation ............................................................ 9-10
9-2.7. Contact Assembly Installation .......................................................................... 9-14
9-2.8. Magneto Internal Timing .................................................................................. 9-16
D 6 L N -3200
Magneto Configuration
S = Single Type Magneto:
one drive, one output distributor
D = Dual Type Magneto:
one drive, two output distributors
DUAL MAGNETO
START SWITCH
OFF
R
C2
L L SWITCH
BOTH MAIN
CONTACT T1
START ASSEMBLY
LR RETARD
STARTING VIBRATOR
RETARD
24V ONLY
CONTACT
L2 BO BO ASSEMBLY
L1
V1 IN
R
C1
SPARK PLUG
C3
BAT SWITCH
MAIN
CONTACT T2
ASSEMBLY
+
BATTERY
-
K1
2-5
2-8 2-6 2-7
2-11
ITEMS INCLUDED WITH
10-40040X-XX KITS
OUTER EXTRUDED
SILICONE INSULATION SILICONE RUBBER
PRESSURE
DIRECTION
BEARING
RETAINER
BEARING
STEEL PLATE
LOCALLY
FABRICATED
STEEL SUPPORT
TUBE
LOCALLY
FABRICATED
6.0”
2.5” DIA.
Figure 4-6. Rotor on Support Bars for Small Gear and Bushing Removal
4-3. Harness Disassembly
1. Remove the inner ferrules (Figure 2)(7, 7a or 14) from the outer ferrules (8 or 13) or
cover (16) using 0.25 inch drift and arbor press. Discard all used inner ferrules (7, 7a
or 14).
2. All other harness hardware may be disassembled using standard shop practices.
Discard eyelets (12) and terminals (3) following disassembly.
APPROX.
1/8 IN.
S
AXLE
HEEL TAIL
TRIGGER RAMP
ROTATING MAGNET
SHAFT
ROTOR
HOLDING
TOOL
3 in.
BODY TRIP
DOG (EAR)
X PLUS 0.014
NOT
STOP PIN PERMISSIBLE
DATE CODE
1.00
± 0.08
0.38
STRIP
HEAT SHRINK
1.00 LENGTH
CENTER OVER JOINT
AND SHRINK
HEAT SHRINK TUBING
5.20 LONG
BUTT AGAINST COIL AND
SHRINK
10-400506
CRIMP SLEEVE
SCREW
PLATE
SPRING
NUT
PLATE
SPRING
WASHER SCREW
Left Magneto High Left Main & Retard Right Magneto High
Tension Outlets Breaker Contact Tension Outlets
Assembly
Figure 9-10. Cam End View of Magneto
8. Rotate the cam(s) so the high lobe(s) is (are) under the cam followers of the contact
assemblies. Adjust the left main contact to obtain 0.016 ± 0.002 inch opening.
Check the retard contacts for 0.016 ± 0.004 inch clearance.
CAUTION: Bend the contact assembly frame carefully. It requires
very little movement of the bracket to change the contact opening
clearance. If the bracket is bent too much, do not attempt to bend it
back, as this will weaken the bracket. Use another new contact
assembly.
9. If proper retard contact clearance cannot be obtained, loosen the contact assembly
securing screws (9), move the contact assembly away from the cams, and retighten
the screws. If the clearance was over 0.020 inch, bend the steel upright frame of the
contact assembly away from the cam. If the clearance was under 0.012 inch, bend
the frame toward the cam. Readjust the left main contact assembly for the 0.016 ±
0.002 inch clearance, and recheck the retard clearance.
10. Support the drive end of the rotating magnet (48) shaft on a non-metallic surface,
and install woodruff key(s) (35).
11. Apply a thin film of P/N 646943 anti-seize lubricant to the taper on the rotating
magnet (48) and install a drive plate (37 & 38) or cam assembly (42) over the taper.
Install bushing (34) and nut (32); do not tighten the nut at this time.
CW CCW
Figure 9-16. Impulse Coupling Spring Orientation
CAUTION: Nicks or scratches in the impulse coupling spring will
cause the spring to break.
5. Using a small screwdriver with all sharp edges removed, pry up one and one half
turns at the inner end of the spring and support in the position shown in Figure 9-17.
Do not allow the screwdriver to scratch the spring.
FERRULE
CLAMP
PRIMARY SCREW NUT
10-400105 10-35936-6 10-90404-4
RETENTION
SCREW & NUT
+ .000
1.312 - .005
Diameter
4.0” 1.25”
2.0”
4.0”
2.000” 0.250”
+ 0.015 1.000”
0.625” - 0.000
4.000”
.750”
1.750”
Short
Shaft 2.250”
Long
Shaft
3.500”
3.500”
2.688”
0.250” Dia.
1.344” 2 Places
2.0”
0.187”
1.0”
Needed
As
2.688”
4 3 2 1
5
Figure 11-1. Terminal Kit Spares
10-382555-141
10-382555-151
10-382610-131
10-382610-221
10-382555-12
10-382555-13
10-382555-14
10-382555-15
10-382560-13
10-382605-13
10-382610-13
10-382910-13
10-382910-18
10-382555-11
10-382560-11
10-382610-11
10-382620-11
10-382920-11
Figure 1
Index Description Part No.
Screw, Socket NAS1351-3-32P 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
1
NAS1351-3LB32P 4 4 4
2 Washer, Spring Lock MS35338-43 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
3 Washer, Plain 10-55501 4 4 4
4 Nut, Hex 10-382618 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
5 Washer, Lock 10-17050 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Capacitor, 6 CYL 10-400576 2 2 2 2 2 2 2 2
6 Capacitor, 8 CYL 10-400578 2 2
Capacitor, 4 CYL 10-400574 2 2 2 2 2 2 2 2
7 Pin, Cotter 10-90751-18 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
8 Gasket, Cover 10-382811 1 1 1
9 Screw, w/ Lock washer 10-35936-7 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
10 Washer, Plain 10-14268 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
11 Contact Assembly 10-382585 2 2 2 2 2 1 1 2 2 1 1 1 1 1 1 1
12 Contact Assembly, Main & Tach 10-400183 1 1 1 1
13 Contact Assembly, Main & Retard 10-400184 1 1 1 1 1 1 1 1 1
Screw, w/ Lock washer 10-382959 1 1 1 1 1 1 1 1 1 1 1
14
10-391213 1 1 1 1 1 1 1
15 Washer, Plain 10-51354 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Cam, Breaker, 2 lobe 10-382544 1 1 1 1 1 1 1 1
16
Cam, Breaker, 4 lobe 10-382543 1 1 1 1 1 1 1 1 1 1
Cam, Retard, 4 lobe 10-382739 1 1 1 1 1 1 1 1
17
Cam, Retard, 2 lobe 10-382741 1 1 1
18 Screw, w/ Lock washer 10-35937-20 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
19 DELETED
20 Connector, Strip 10-382785 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Gear Kit, 4 & 8 CYL 10-682014 2 2 2 2 2 2 2 2 2 2
21
Gear Kit, 6 CYL 10-682016 2 2 2 2 2 2 2 2
22 Ring, Retaining MS16624-2037 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
23 Washer, Flat 10-349511 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
24 Brush, Carbon 10-160844 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
25 Washer, Nylon 10-391309 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
26 Washer, Felt 10-50752 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Block & Bearing Kit, 4 CYL 10-682054 1 1 1 1 1 1 1 1
27 Block & Bearing Kit, 6 CYL 10-682056 1 1 1 1 1 1 1 1
Block & Bearing Kit, 8 CYL 10-682058 1 1
28 Strip, Felt 10-163374 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
29 Spring, Helical 10-50737 8 8 8 8 8 8 8 12 12 8 12 12 12 12 16 12 12 16
30 Bearing, Roller 10-400553 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
31 Washer, Plain 10-685548 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
10-382555-141
10-382555-151
10-382610-131
10-382610-221
10-382555-12
10-382555-13
10-382555-14
10-382555-15
10-382560-13
10-382605-13
10-382610-13
10-382910-13
10-382910-18
10-382555-11
10-382560-11
10-382610-11
10-382620-11
10-382920-11
Figure 1
Index Description Part No.
Nut, Castellated 10-51643 1 1
32
10-163178 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
33 Washer, Lock 10-3793 1 1
34 Bushing, Drive 10-163048 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
35 Key, Woodruff 10-90788-5 2 1 2 2 2 2 2 2 2 2 2 2 2 1 2 2 2 2
Washer, Plain 10-4093 1
36 10-52307 1
10-116860 1 1 1 1 1 1 1 1
Driveplate 10-349932-2 1 1 1 1 1 1 1
37
10-349932-3 1
38 Driveplate 10-349933-9 1
Coupling, Impulse, CCW, 25° 10-400323 1
Coupling, Impulse, CW, 20° 10-400311 1 1 1
Coupling, Impulse, CCW, 15° 10-400322 1
39
Coupling, Impulse, CCW, 20° 10-400324 1 1
Coupling, Impulse, CCW, 15° 10-400325 1
Coupling, Impulse, CCW, 10° 10-400326 1
Body, Impulse Coupling 10-382747 1
10-382768 1 1 1
10-382748 1
40
10-382767 1 1
10-382952 1
10-382961 1
Spring, Flat, Spiral 10-51324 1 1 1 1 1 1 1
41
10-400042 1 1
Cam Assembly, Impulse 10-400167-9 1
10-400166-7 1 1 1
10-400167-7 1
42
10-400167-8 1 1
10-400167-13 1
10-400167-12 1
43 Ring, Retaining MS16624-2062 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
44 Washer, Plain 10-349328 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
45 Washer, Bowed 10-349249 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
46 Screw, Socket Head, Locking 10-382789 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
47 Washer, Plain 10-382788 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Magnet, Rotating 10-382799-1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
48
10-382799-2 1 1
49 Slinger, Oil 10-349248 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
50 Bearing, Ball 10-400567 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
51 Plate, Bearing Retainer 10-382787 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Gear, Spur, 4 & 8 CYL 10-382573 1 1 1 1 1 1 1 1 1 1
52
Gear, Spur, 6 CYL 10-382575 1 1 1 1 1 1 1 1
10-382555-141
10-382555-151
10-382610-131
10-382610-221
10-382555-12
10-382555-13
10-382555-14
10-382555-15
10-382560-13
10-382605-13
10-382610-13
10-382910-13
10-382910-18
10-382555-11
10-382560-11
10-382610-11
10-382620-11
10-382920-11
Figure 1
Index Description Part No.
53 Bushing, Roller Bearing 10-382969 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Kit, Coil Securing 10-382939 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
54a Screw, Cap NAS1352-08-24P 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
54b Washer 10-382788 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
54c Nut, Self-Locking 10-382936 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
55 Plate, Coil Retaining 10-382935 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
56 Spring 10-382931 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
57 Strip, Paper 10-382568 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Coil, 6 & 8 CYL. 10-382588-1 2 2 2 2 2 2 2 2 2 2
58
Coil, 6 & 8 CYL. 10-382790-1 2 2 2 2 2 2 2 2
59 Plug, Ventilator 10-157134 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
60 Plug, Solid Nylon 10-157135 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
61 Bushing, Threaded 10-382815 1 1 1
62 Orifice, Threaded 10-382861 1 1 1
63 Plug, Solid Aluminum 10-51391 2 2 2
64 Plate, Identification 10-400006 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
65 Housing, Magneto NP1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
10-682555-141
10-682555-151
10-682560-131
10-682610-131
10-682610-221
10-682555-12
10-682555-13
10-682555-14
10-682555-15
10-682555-16
10-682560-13
10-682605-13
10-682610-13
10-682910-13
10-682910-18
10-682555-11
10-682560-11
10-682610-11
10-682620-11
10-682920-11
Figure 1
Index Description Part No.
1 Screw, Socket NAS1351-3-32P 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
NAS1351-3LB32P 4 4 4
2 Washer, Spring Lock MS35338-43 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
3 Washer, Plain 10-55501 4 4 4
4 Nut, Hex 10-382618 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
5 Washer, Lock 10-17050 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
6 Capacitor, 6 CYL 10-400576 2 2 2 2 2 2 2 2 2
Capacitor, 8 CYL 10-400578 2 2
Capacitor, 4 CYL 10-400574 2 2 2 2 2 2 2 2 2
7 Pin, Cotter 10-90751-18 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
8 Gasket, Cover 10-382811 1 1 1
9 Screw, w/ Lock washer 10-35936-7 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
10 Washer, Plain 10-14268 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
11 Contact Assembly 10-382585 2 2 2 2 2 2 1 1 2 2 1 1 1 1 1 1 1 1
12 Contact Assembly, Main & Tach 10-400183 1 1 1 1 1
13 Contact Assembly, Main & Retard 10-400184 1 1 1 1 1 1 1 1 1
14 Screw, w/ Lock washer 10-382959 1 1 1 1 1 1 1 1 1 1 1 1
10-391213 1 1 1 1 1 1 1 1
15 Washer, Plain 10-51354 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
16 Cam, Breaker, 2 lobe 10-382544 1 1 1 1 1 1 1 1 1
Cam, Breaker, 4 lobe 10-382543 1 1 1 1 1 1 1 1 1 1 1
17 Cam, Retard/Tach., 4 lobe 10-382739 1 1 1 1 1 1 1 1 1
Cam, Retard/Tach., 2 lobe 10-382741 1 1 1 1 1 1 1 1 1 1 1
18 Screw, w/ Lock washer 10-35937-20 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
19 DELETED
20 Connector, Strip 10-382785 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
21 Gear Kit, 4 & 8 CYL 10-682014 2 2 2 2 2 2 2 2 2 2 2
Gear Kit, 6 CYL 10-682016 2 2 2 2 2 2 2 2 2
22 Ring, Retaining MS16624-2037 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
23 Washer, Flat 10-349511 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
24 Brush, Carbon 10-160844 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
25 Washer, Nylon 10-391309 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
26 Washer, Felt 10-50752 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
27 Block & Bearing Kit, 4 CYL 10-682054 1 1 1 1 1 1 1 1 1
Block & Bearing Kit, 6 CYL 10-682056 1 1 1 1 1 1 1 1 1
Block & Bearing Kit, 8 CYL 10-682058 1 1
28 Strip, Felt 10-163374 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
29 Spring, Helical 10-50737 8 8 8 8 8 8 8 8 12 12 12 8 12 12 12 12 16 12 12 16
30 Bearing, Roller 10-400553 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
31 Washer, Plain 10-685548 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
32 Nut, Castellated 10-51643 1 1
10-163178 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
33 Washer, Lock 10-3793 1 1
10-682555-141
10-682555-151
10-682560-131
10-682610-131
10-682610-221
10-682555-12
10-682555-13
10-682555-14
10-682555-15
10-682555-16
10-682560-13
10-682605-13
10-682610-13
10-682910-13
10-682910-18
10-682555-11
10-682560-11
10-682610-11
10-682620-11
10-682920-11
Figure 1
Index Description Part No.
34 Bushing, Drive 10-163048 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
35 Key, Woodruff 10-90788-5 2 1 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 2 2 2
36 Washer, Plain 10-4093 1
10-52307 1
10-116860 1 1 1 1 1 1 1 1 1 1
37 Driveplate 10-349932-2 1 1 1 1 1 1 1
10-349932-3 1
38 Driveplate 10-349933-9 1
39 Coupling, Impulse, CCW, 25° 10-400323 1
Coupling, Impulse, CW, 20° 10-400311 1 1 1
Coupling, Impulse, CCW, 15° 10-400322 1
Coupling, Impulse, CCW, 20° 10-400324 1 1
Coupling, Impulse, CCW, 15° 10-400325 1
Coupling, Impulse, CCW, 10° 10-400326 1 1
Coupling, Impulse, CW, 15° 10-400310 1
40 Body, Impulse Coupling 10-382747 1
10-382768 1 1 1
10-382748 1
10-382767 1 1
10-382952 1
10-382961 1 1
10-382749 1
41 Spring, Flat, Spiral 10-51324 1 1 1 1 1 1 1 1
10-400042 1 1 1
42 Cam Assembly, Impulse 10-400167-9 1
10-400166-7 1 1 1
10-400167-7 1
10-400167-8 1 1
10-400167-12 1 1
10-400167-13 1
10-400166-5 1
43 Ring, Retaining MS16624-2062 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
44 Washer, Plain 10-349328 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
45 Washer, Bowed 10-349249 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
46 Screw, Socket Head, Locking 10-382789 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
47 Washer, Plain 10-382788 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
48 Magnet, Rotating 10-382799-1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
10-382799-2 1 1
49 Slinger, Oil 10-349248 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
50 Bearing, Ball 10-400567 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
51 Plate, Bearing Retainer 10-382787 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
52 Gear, Spur, 4 & 8 CYL 10-382573 1 1 1 1 1 1 1 1 1 1 1
Gear, Spur, 6 CYL 10-382575 1 1 1 1 1 1 1 1 1
10-682555-141
10-682555-151
10-682560-131
10-682610-131
10-682610-221
10-682555-12
10-682555-13
10-682555-14
10-682555-15
10-682555-16
10-682560-13
10-682605-13
10-682610-13
10-682910-13
10-682910-18
10-682555-11
10-682560-11
10-682610-11
10-682620-11
10-682920-11
Figure 1
Index Description Part No.
53 Bushing, Roller Bearing 10-382969 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
54 Screw, W/ Lock washer 10-682024 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
55 Plate, Coil Retaining 10-382935 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
56 Spring 10-382931 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
57 Strip, Paper 10-382568 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
58 Coil, 6 & 8 CYL 10-382588-1 2 2 2 2 2 2 2 2 2 2 2
Coil, 4 CYL 10-382790-1 2 2 2 2 2 2 2 2 2
59 Plug, Ventilator 10-157134 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
60 Plug, Solid Nylon 10-157135 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
61 Bushing, Threaded 10-382815 1 1 1
62 Orifice, Threaded 10-382861 1 1 1
63 Plug, Solid Aluminum 10-51391 2 2 2
64 Plate, Identification 10-400006 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
65 Housing, Magneto 10-682000-1 1 1 1 1 1 1 1 1 1
Housing, Magneto 10-682000-2 1 1 1 1 1 1 1 1
Housing, Magneto 10-682000-4 1 1 1
10-720633-48
10-720633-78
10-821412-93
10-821414-10
10-821414-14
10-821414-18
10-821415-12
10-821425-12
10-821414-4
10-821414-6
10-821414-8
10-821444-6
Figure 2
Index Description Part No.
1 Lead Kit, 3/4-20, 48 in. 10-400401-48 8 4 4 6 3 5 6 6 4
Lead Kit, 3/4-20, 78 in. 10-400401-78 4 4 2 5 3 2 2 4
Lead Kit, 5/8-24, 48 in. 10-400402-48 8
2 Spring 10-32326 X X 8 8 8 8 8 8 8 8 8 8
3 Terminal, Wire 10-320467 1 1 8 8 8 8 8 8 8 8 8
10-320468 8
4 Sleeve, Insulating 10-400099 8 8 8 8 8 8 8 8 8
10-320473 8
110-400101 X X
5 Eyelet, Compression 10-400097 8 8 8 8 8 8 8 8 8
6 Spring, Compression 10-400195 8 8 8 8 8 8 8 8 8
7 Eyelet, Retention 10-400093 16 16 16 16 16 16 16 16 16 16
7A Ferrule, Inner 10-620109 1 1
8 Ferrule 10-400137 8 8 8 8 8 8 8 8 8
10-400081 8
9 Nut, Hex, Coupling 10-400187 8
10-400186 8
10 Cable, 5mm, 100 ft. 10-400062-1 AR AR AR AR AR AR AR AR AR AR AR AR
11 Grommet 10-320777 X X 8 8 8 8 8 8 8 8 8 8
12 Eyelet 10-163012 1 1 8 8 8 8 8 8 8 8 8 8
13 Ferrule, Outer1 10-620024 1 1
14 10-620011 1 1
Ferrule, Inner1
15 Elbow, 110° NP2 X X
16 Cover, 4 CYL, Plain 10-400124-1 1 1 1 1 1 1 1 1
Cover, 4 CYL, Retard 10-400124-2 1 1
Cover, 4 CYL, Tach 10-400124-4 1
17 Kit, Elbow Clamp, 4 CYL 10-400112-8 1 1 1
18 Clamp, Primary 10-400105 8 8 8
19 Clamp, Secondary 10-400107 8 8 8
20 Screw, w/ Lock washer 10-35936-6 8 8 8
21 Nut MS35649-282 8 8 8
22 Tie, Cable 10-620013 10 25 16 22 25 28 19 18 18 16
23 Clamp, 1 wire MS21333-98 2 5 2 2 2 1 1 5
24 Clamp, 2 - 3 wire MS21333-102 6 2 3 3 2 2 3 3 3 3
25 Clamp, 4 wire MS21919WCG10 2 2 2 3 2 1 2 2 2 2
26 Clamp, 6 wire MS21919WCG12 1 1 1
27 Bracket, Twist 10-400060-2 1
10-400060-3 2 2 2
28 Screw 10-35937-10 2 1 2 2
29 Lock nut MS21044N3 2 1 2 2
30 Plate, Cable Support 10-620039-2 4
10-620039-3 2
10-620039-4 2 2
10-620039-5 2 4 4 2
31 Grommet 10-320163 2
MS35489-9 4
1. Elbow leads available only until supply on hand is exhausted
2. No Parts Available
Table 11-8. 6 & 8 Cylinder D-2000 and D-3000 Gold Seal® Harnesses
10-821614-36
10-821615-20
10-821625-34
10-821635-11
10-821614-6
10-821615-4
10-821624-6
10-821625-4
10-821635-4
10-821644-6
10-821825-2
Figure 2
Index Description Part No.
1 Lead Kit, 3/4-20, 48 in. 10-400401-48 4 8 5 2 4 5 6 5 9 4 79
Lead Kit, 3/4-20, 78 in. 10-400401-78 8 4 7 10 8 7 6 7 3 8 9
2 Spring 10-32326 12 12 12 12 12 12 12 12 12 12 16
3 Terminal, Wire 10-320467 12 12 12 12 12 12 12 12 12 12 16
4 Sleeve, Insulating 10-400099 12 12 12 12 12 12 12 12 12 12 16
5 Eyelet, Compression 10-400097 12 12 12 12 12 12 12 12 12 12 16
6 Spring, Compression 10-400195 12 12 12 12 12 12 12 12 12 12 16
7 Eyelet, Retention 10-400093 24 24 24 24 24 24 24 24 24 24 32
8 Ferrule 10-400137 12 12 12 12 12 12 12 12 12 12 16
9 Nut, Hex, Coupling 10-400187 12 12 12 12 12 12 12 12 12 12 16
10 Clamp, 5mm, 100 ft. 10-400062-1 AR AR AR AR AR AR AR AR AR AR AR
11 Grommet 10-320777 12 12 12 12 12 12 12 12 12 12 16
12 Eyelet 10-163012 12 12 12 12 12 12 12 12 12 12 16
16 Cover, 6 CYL, Plain 10-400126-1 1 1 1 1
Cover, 6 CYL, Retard 10-400126-2 1 1 1
Cover, 6 CYL, Tach/Ret 10-400126-3 1 1
Cover, 6 CYL, Tach 10-400126-4 1
Cover, 8 CYL, Retard 10-400128-2 1
17 Kit, Elbow Clamp, 4 CYL 10-400112-8 2
Kit, Elbow Clamp, 6 CYL 10-400112-12 1 1 1 1 1 1
18 Clamp, Primary 10-400105 12 12 12 12 12 12 16
19 Clamp, Secondary 10-400107 12 12 12 12 12 12 16
20 Screw, w/ Lock washer 10-35936-6 12 12 12 12 12 12 16
21 Nut MS35649-282 12 12 12 12 12 12 16
22 Tie, Cable 10-620013 26 31 31 18 26 31 28 31 20 26 29
23 Clamp, 1 wire MS21333-98 6 4 6 3 6 6 4 6 6 2
24 Clamp, 2 - 3 wire MS21333-102 5 7 6 5 5 6 10 6 3 5 10
25 Clamp, 4 wire MS21919WCG10 3
26 Clamp, 6 wire MS21919WCG12 3 4 1 4 3 1 1 1 2 3
27 Bracket, Twist 10-400060-2 2 1 2
10-400060-3 1 2
10-400060-7 1 2
28 Screw 10-35937-10 3 2 1 2 2
29 Lock nut MS21044N3 3 2 1 2 2
30 Plate, Cable Support 10-620039-1 2 4 2 4 2
10-620039-2 4
10-620039-3 2 2 2
10-620039-4 4
31 Bracket 10-78916 1
32 Clamp, 8 wire MS21919WCG14 4
64
65
31
D-2000/D-3000 Series High Tension Magneto Service Support Manual 11-17(Reverse Blank)
31 August 2011
Illustrasted Parts List
32
D-2000/D-3000 Series High Tension Magneto Service Support Manual 11-18(Reverse Blank)
31 August 2011
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